Ford - Expedition 4wd - Workshop Manual - 2006 - 2006

Factory Workshop Manual Make Ford Model Expedition 4wd Engine and year V8-5.4L VIN 5 (2006) 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0005 - P0009, ( P0006 P0007 P0008 0005 0006 0007 0008 0009 ) > System Information > System Diagnosis P0005 - P0009: Testing and Inspection For diagnosis of code P005x, refer to chart: P005x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0010 - P0014, ( P0011 P0012 P0013 0010 0011 0012 0013 0014 ) > System Information > System Diagnosis > P0010 P0010 - P0014: Testing and Inspection P0010 For diagnosis of code P0010, refer to chart: P0010 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0010 - P0014, ( P0011 P0012 P0013 0010 0011 0012 0013 0014 ) > System Information > System Diagnosis > P0010 > Page 12 P0010 - P0014: Testing and Inspection P0011 For diagnosis of code P0011, refer to chart: P0011 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0010 - P0014, ( P0011 P0012 P0013 0010 0011 0012 0013 0014 ) > System Information > System Diagnosis > P0010 > Page 13 P0010 - P0014: Testing and Inspection P0012 For diagnosis of code P0012, refer to chart: P0012 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0015 - P0019, ( P0016 P0017 P0018 0015 0016 0017 0018 0019 ) > System Information > System Diagnosis > P0016 P0015 - P0019: Testing and Inspection P0016 For diagnosis of code P, refer to chart: P0016 P0016 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0015 - P0019, ( P0016 P0017 P0018 0015 0016 0017 0018 0019 ) > System Information > System Diagnosis > P0016 > Page 18 P0015 - P0019: Testing and Inspection P0018 For diagnosis of code P0018, refer to chart: P0018 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0020 - P0024, ( P0021 P0022 P0023 0020 0021 0022 0023 0024 ) > System Information > System Diagnosis > P0020 P0020 - P0024: Testing and Inspection P0020 For diagnosis of code P0020, refer to chart: P0020 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0020 - P0024, ( P0021 P0022 P0023 0020 0021 0022 0023 0024 ) > System Information > System Diagnosis > P0020 > Page 23 P0020 - P0024: Testing and Inspection P0021 For diagnosis of code P0021, refer to chart: P0021 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0020 - P0024, ( P0021 P0022 P0023 0020 0021 0022 0023 0024 ) > System Information > System Diagnosis > P0020 > Page 24 P0020 - P0024: Testing and Inspection P0022 For diagnosis of code P0022, refer to chart: P0022 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0040 - P0044, ( P0041 P0042 P0043 0040 0041 0042 0043 0044 ) > System Information > System Diagnosis > P0040 P0040 - P0044: Testing and Inspection P0040 For diagnosis of code P0040, refer to chart: P0040 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0040 - P0044, ( P0041 P0042 P0043 0040 0041 0042 0043 0044 ) > System Information > System Diagnosis > P0040 > Page 29 P0040 - P0044: Testing and Inspection P0041 For diagnosis of code P0041, refer to chart: P0041 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0050 - P0054, ( P0051 P0052 P0053 0050 0051 0052 0053 0054 ) > System Information > System Diagnosis > P0053 P0050 - P0054: Testing and Inspection P0053 For diagnosis of code P0053, refer to chart: If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0050 - P0054, ( P0051 P0052 P0053 0050 0051 0052 0053 0054 ) > System Information > System Diagnosis > P0053 > Page 34 P0050 - P0054: Testing and Inspection P0054 For diagnosis of code P0054, refer to chart: If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0055 - P0059, ( P0056 P0057 P0058 0055 0056 0057 0058 0059 ) > System Information > System Diagnosis > P0055 P0055 - P0059: Testing and Inspection P0055 For diagnosis of code P0055, refer to chart: If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0055 - P0059, ( P0056 P0057 P0058 0055 0056 0057 0058 0059 ) > System Information > System Diagnosis > P0055 > Page 39 P0055 - P0059: Testing and Inspection P0059 For diagnosis of code P0059, refer to chart: If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0060 - P0064, ( P0061 P0062 P0063 0060 0061 0062 0063 0064 ) > System Information > System Diagnosis P0060 - P0064: Testing and Inspection For diagnosis of code P0060, refer to chart: P0060 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0065 - P0069, ( P0066 P0067 P0068 0065 0066 0067 0068 0069 ) > System Information > System Diagnosis P0065 - P0069: Testing and Inspection For diagnosis of code P0068, refer to chart: P0068 P0068 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0100 - P0104, ( P0101 P0102 P0103 0100 0101 0102 0103 0104 ) > System Information > System Diagnosis > P0102 P0100 - P0104: Testing and Inspection P0102 For diagnosis of code P0102, refer to chart: P0102 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0100 - P0104, ( P0101 P0102 P0103 0100 0101 0102 0103 0104 ) > System Information > System Diagnosis > P0102 > Page 51 P0100 - P0104: Testing and Inspection P0103 For diagnosis of code P0103, refer to chart: P0103 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0100 - P0104, ( P0101 P0102 P0103 0100 0101 0102 0103 0104 ) > System Information > System Diagnosis > P0102 > Page 52 P0100 - P0104: Testing and Inspection P0104 For diagnosis of code P0104, refer to chart: P0104 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 P0105 - P0109: Testing and Inspection P0106 For diagnosis of code P0106, refer to chart: P0106 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 57 P0105 - P0109: Testing and Inspection P0107 For diagnosis of code P0107, refer to chart: P0107 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 58 P0105 - P0109: Testing and Inspection P0108 For diagnosis of code P0108, refer to chart: P0108 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 59 P0105 - P0109: Testing and Inspection P0109 For diagnosis of code P0109, refer to chart: P0109 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0110 - P0114, ( P0111 P0112 P0113 0110 0111 0112 0113 0114 ) > System Information > System Diagnosis > P0112 P0110 - P0114: Testing and Inspection P0112 For diagnosis of code P, refer to chart: P0112 P0112 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0110 - P0114, ( P0111 P0112 P0113 0110 0111 0112 0113 0114 ) > System Information > System Diagnosis > P0112 > Page 64 P0110 - P0114: Testing and Inspection P0113 For diagnosis of code P0113, refer to chart: P0113 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0110 - P0114, ( P0111 P0112 P0113 0110 0111 0112 0113 0114 ) > System Information > System Diagnosis > P0112 > Page 65 P0110 - P0114: Testing and Inspection P0114 For diagnosis of code P0114, refer to chart: P0114 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119, ( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 P0115 - P0119: Testing and Inspection P0116 For diagnosis of code P0116, refer to chart: P0116 P0116 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119, ( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 > Page 70 P0115 - P0119: Testing and Inspection P0117 For diagnosis of code P0117, refer to chart: P0117 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119, ( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 > Page 71 P0115 - P0119: Testing and Inspection P0118 For diagnosis of code P0118, refer to chart: P0118 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119, ( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 > Page 72 P0115 - P0119: Testing and Inspection P0119 For diagnosis of code P0119, refer to chart: P0119 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124, ( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 P0120 - P0124: Testing and Inspection P0121 For diagnosis of code P0121, refer to chart: P0121 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124, ( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 77 P0120 - P0124: Testing and Inspection P0122 For diagnosis of code P0122, refer to chart: P0122 P0122 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124, ( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 78 P0120 - P0124: Testing and Inspection P0123 For diagnosis of code P0123, refer to chart: P0123 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0125 - P0129, ( P0126 P0127 P0128 0125 0126 0127 0128 0129 ) > System Information > System Diagnosis > P0125 P0125 - P0129: Testing and Inspection P0125 For diagnosis of code P0125, refer to chart: P0125 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0125 - P0129, ( P0126 P0127 P0128 0125 0126 0127 0128 0129 ) > System Information > System Diagnosis > P0125 > Page 83 P0125 - P0129: Testing and Inspection P0127 For diagnosis of code P0127, refer to chart: P0127 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0125 - P0129, ( P0126 P0127 P0128 0125 0126 0127 0128 0129 ) > System Information > System Diagnosis > P0125 > Page 84 P0125 - P0129: Testing and Inspection P0128 For diagnosis of code P0128, refer to chart: P0128 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0130 - P0134, ( P0131 P0132 P0133 0130 0131 0132 0133 0134 ) > System Information > System Diagnosis > P0132 P0130 - P0134: Testing and Inspection P0132 For diagnosis of code P0132, refer to chart: P0132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0130 - P0134, ( P0131 P0132 P0133 0130 0131 0132 0133 0134 ) > System Information > System Diagnosis > P0132 > Page 89 P0130 - P0134: Testing and Inspection P0133 For diagnosis of code P0133, refer to chart: P0133 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0135 - P0139, ( P0136 P0137 P0138 0135 0136 0137 0138 0139 ) > System Information > System Diagnosis > P0135 P0135 - P0139: Testing and Inspection P0135 For diagnosis of code P0135, refer to chart: P0135 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0135 - P0139, ( P0136 P0137 P0138 0135 0136 0137 0138 0139 ) > System Information > System Diagnosis > P0135 > Page 94 P0135 - P0139: Testing and Inspection P0138 For diagnosis of code P0138, refer to chart: P0138 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0140 - P0144, ( P0141 P0142 P0143 0140 0141 0142 0143 0144 ) > System Information > System Diagnosis > P0141 P0140 - P0144: Testing and Inspection P0141 For diagnosis of code P0141, refer to chart: P0141 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0140 - P0144, ( P0141 P0142 P0143 0140 0141 0142 0143 0144 ) > System Information > System Diagnosis > P0141 > Page 99 P0140 - P0144: Testing and Inspection P0144 For diagnosis of code P0144, refer to chart: P0144 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0145 - P0149, ( P0146 P0127 P0148 0145 0146 0147 0148 0149 ) > System Information > System Diagnosis > P0147 P0145 - P0149: Testing and Inspection P0147 For diagnosis of code P0147, refer to chart: P0147 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0145 - P0149, ( P0146 P0127 P0148 0145 0146 0147 0148 0149 ) > System Information > System Diagnosis > P0147 > Page 104 P0145 - P0149: Testing and Inspection P0148 For diagnosis of code P0148, refer to chart: P0148 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0150 - P0154, ( P0151 P0152 P0153 0150 0151 0152 0153 0154 ) > System Information > System Diagnosis > P0152 P0150 - P0154: Testing and Inspection P0152 For diagnosis of code P0152, refer to chart: P0152 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0150 - P0154, ( P0151 P0152 P0153 0150 0151 0152 0153 0154 ) > System Information > System Diagnosis > P0152 > Page 109 P0150 - P0154: Testing and Inspection P0153 For diagnosis of code P0153, refer to chart: P0153 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0155 - P0159, ( P0156 P0157 P0158 0155 0156 0157 0158 0159 ) > System Information > System Diagnosis > P0155 P0155 - P0159: Testing and Inspection P0155 For diagnosis of code P0155, refer to chart: P0155 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0155 - P0159, ( P0156 P0157 P0158 0155 0156 0157 0158 0159 ) > System Information > System Diagnosis > P0155 > Page 114 P0155 - P0159: Testing and Inspection P0158 For diagnosis of code P0158, refer to chart: P0158 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0160 - P0164, ( P0161 P0162 P0163 0160 0161 0162 0163 0164 ) > System Information > System Diagnosis P0160 - P0164: Testing and Inspection For diagnosis of code P0161, refer to chart: P0161 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174, ( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 P0170 - P0174: Testing and Inspection P0171 For diagnosis of code P0171, refer to chart: P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174, ( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 122 P0170 - P0174: Testing and Inspection P0172 For diagnosis of code P0172, refer to chart: P0172 P0172 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174, ( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 123 P0170 - P0174: Testing and Inspection P0174 For diagnosis of code P0174, refer to chart: P0174 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0175 - P0179, ( P0176 P0177 P0178 0175 0176 0177 0178 0179 ) > System Information > System Diagnosis P0175 - P0179: Testing and Inspection For diagnosis of code P0175, refer to chart: P0175 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 P0180 - P0184: Testing and Inspection P0180 For diagnosis of code P0180, refer to chart: P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 131 P0180 - P0184: Testing and Inspection P0181 For diagnosis of code P0181, refer to chart: P0181 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 132 P0180 - P0184: Testing and Inspection P0182 For diagnosis of code P0182, refer to chart: P0182 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 133 P0180 - P0184: Testing and Inspection P0183 For diagnosis of code P0183, refer to chart: P0183 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 P0190 - P0194: Testing and Inspection P0190 For diagnosis of code P0190, refer to chart: P0190 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 138 P0190 - P0194: Testing and Inspection P0191 For diagnosis of code P0191, refer to chart: P0191 P0191 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 139 P0190 - P0194: Testing and Inspection P0192 For diagnosis of code P0192, refer to chart: P0192 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 140 P0190 - P0194: Testing and Inspection P0193 For diagnosis of code P0193, refer to chart: P0193 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0195 - P0199, ( P0196 P0197 P0198 0195 0196 0197 0198 0199 ) > System Information > System Diagnosis > P0196 P0195 - P0199: Testing and Inspection P0196 For diagnosis of code P0196, refer to chart: P0196 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0195 - P0199, ( P0196 P0197 P0198 0195 0196 0197 0198 0199 ) > System Information > System Diagnosis > P0196 > Page 145 P0195 - P0199: Testing and Inspection P0197 For diagnosis of code P0197, refer to chart: P0197 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0195 - P0199, ( P0196 P0197 P0198 0195 0196 0197 0198 0199 ) > System Information > System Diagnosis > P0196 > Page 146 P0195 - P0199: Testing and Inspection P0198 For diagnosis of code P0198, refer to chart: P0198 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis P0200 - P0204: Testing and Inspection For diagnosis of code P020X, refer to chart: P020x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214, ( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis P0210 - P0214: Testing and Inspection For diagnosis of code P0210, refer to chart: P0210 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0215 - P0219, ( P0216 P0217 P0218 0215 0216 0217 0218 0219 ) > System Information > System Diagnosis > P0217 P0215 - P0219: Testing and Inspection P0217 For diagnosis of code P0217, refer to chart: P0217 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0215 - P0219, ( P0216 P0217 P0218 0215 0216 0217 0218 0219 ) > System Information > System Diagnosis > P0217 > Page 158 P0215 - P0219: Testing and Inspection P0218 For diagnosis of code P0218, refer to chart: P0218 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0215 - P0219, ( P0216 P0217 P0218 0215 0216 0217 0218 0219 ) > System Information > System Diagnosis > P0217 > Page 159 P0215 - P0219: Testing and Inspection P0219 For diagnosis of code P0219, refer to chart: P0219 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0220 - P0224, ( P0221 P0222 P0223 0220 0221 0222 0223 0224 ) > System Information > System Diagnosis > P0221 P0220 - P0224: Testing and Inspection P0221 For diagnosis of code P0221, refer to chart: P0221 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0220 - P0224, ( P0221 P0222 P0223 0220 0221 0222 0223 0224 ) > System Information > System Diagnosis > P0221 > Page 164 P0220 - P0224: Testing and Inspection P0222 For diagnosis of code P0222, refer to chart: P0222 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0220 - P0224, ( P0221 P0222 P0223 0220 0221 0222 0223 0224 ) > System Information > System Diagnosis > P0221 > Page 165 P0220 - P0224: Testing and Inspection P0223 For diagnosis of code P0223, refer to chart: P0223 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 P0230 - P0234: Testing and Inspection P0230 For diagnosis of code P0230, refer to chart: P0230 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 170 P0230 - P0234: Testing and Inspection P0231 For diagnosis of code P0231, refer to chart: P0231 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 171 P0230 - P0234: Testing and Inspection P0232 For diagnosis of code P0232, refer to chart: P0232 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 172 P0230 - P0234: Testing and Inspection P0234 For diagnosis of code P0234, refer to chart: P0234 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0240 - P0244, ( P0241 P0242 P0243 0240 0241 0242 0243 0244 ) > System Information > System Diagnosis P0240 - P0244: Testing and Inspection For diagnosis of code P0243, refer to chart: P0243 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0260 - P0264, ( P0261 P0262 P0263 0260 0261 0262 0263 0264 ) > System Information > System Diagnosis > P0261 P0260 - P0264: Testing and Inspection P0261 For diagnosis of code P0261, refer to chart: P0261 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0260 - P0264, ( P0261 P0262 P0263 0260 0261 0262 0263 0264 ) > System Information > System Diagnosis > P0261 > Page 180 P0260 - P0264: Testing and Inspection P0262 For diagnosis of code P0262, refer to chart: P0262 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0260 - P0264, ( P0261 P0262 P0263 0260 0261 0262 0263 0264 ) > System Information > System Diagnosis > P0261 > Page 181 P0260 - P0264: Testing and Inspection P0264 For diagnosis of code P0264, refer to chart: P0264 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0265 - P0269, ( P0266 P0267 P0268 0265 0266 0267 0268 0269 ) > System Information > System Diagnosis > P0265 P0265 - P0269: Testing and Inspection P0265 For diagnosis of code P0265, refer to chart: P0265 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0265 - P0269, ( P0266 P0267 P0268 0265 0266 0267 0268 0269 ) > System Information > System Diagnosis > P0265 > Page 186 P0265 - P0269: Testing and Inspection P0267 For diagnosis of code P0267, refer to chart: P0267 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0265 - P0269, ( P0266 P0267 P0268 0265 0266 0267 0268 0269 ) > System Information > System Diagnosis > P0265 > Page 187 P0265 - P0269: Testing and Inspection P0268 For diagnosis of code P0268, refer to chart: P0268 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0270 - P0274, ( P0271 P0272 P0273 0270 0271 0272 0273 0274 ) > System Information > System Diagnosis > P0270 P0270 - P0274: Testing and Inspection P0270 For diagnosis of code P0270, refer to chart: P0270 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0270 - P0274, ( P0271 P0272 P0273 0270 0271 0272 0273 0274 ) > System Information > System Diagnosis > P0270 > Page 192 P0270 - P0274: Testing and Inspection P0271 For diagnosis of code P0271, refer to chart: P0271 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0270 - P0274, ( P0271 P0272 P0273 0270 0271 0272 0273 0274 ) > System Information > System Diagnosis > P0270 > Page 193 P0270 - P0274: Testing and Inspection P0273 For diagnosis of code P0273, refer to chart: P0273 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0270 - P0274, ( P0271 P0272 P0273 0270 0271 0272 0273 0274 ) > System Information > System Diagnosis > P0270 > Page 194 P0270 - P0274: Testing and Inspection P0274 For diagnosis of code P0274, refer to chart: P0274 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0275 - P0279, ( P0276 P0277 P0278 0275 0276 0277 0278 0279 ) > System Information > System Diagnosis > P0276 P0275 - P0279: Testing and Inspection P0276 For diagnosis of code P0276, refer to chart: P0276 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0275 - P0279, ( P0276 P0277 P0278 0275 0276 0277 0278 0279 ) > System Information > System Diagnosis > P0276 > Page 199 P0275 - P0279: Testing and Inspection P0277 For diagnosis of code P0277, refer to chart: P0277 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0275 - P0279, ( P0276 P0277 P0278 0275 0276 0277 0278 0279 ) > System Information > System Diagnosis > P0276 > Page 200 P0275 - P0279: Testing and Inspection P0279 For diagnosis of code P0279, refer to chart: P0279 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0280 - P0284, ( P0281 P0282 P0283 0280 0281 0282 0283 0284 ) > System Information > System Diagnosis > P0280 P0280 - P0284: Testing and Inspection P0280 For diagnosis of code P0280, refer to chart: P0280 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0280 - P0284, ( P0281 P0282 P0283 0280 0281 0282 0283 0284 ) > System Information > System Diagnosis > P0280 > Page 205 P0280 - P0284: Testing and Inspection P0282 For diagnosis of code P0282, refer to chart: P0283 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0280 - P0284, ( P0281 P0282 P0283 0280 0281 0282 0283 0284 ) > System Information > System Diagnosis > P0280 > Page 206 P0280 - P0284: Testing and Inspection P0283 For diagnosis of code P0283, refer to chart: P0283 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0295 - P0299, ( P0296 P0297 P0298 0295 0296 0297 0298 0299 ) > System Information > System Diagnosis > P0297 P0295 - P0299: Testing and Inspection P0297 For diagnosis of code P0297, refer to chart: P0297 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0295 - P0299, ( P0296 P0297 P0298 0295 0296 0297 0298 0299 ) > System Information > System Diagnosis > P0297 > Page 211 P0295 - P0299: Testing and Inspection P0298 For diagnosis of code P0298, refer to chart: P0298 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P030x P0300 - P0304: Testing and Inspection P030x For diagnosis of code P030X, refer to chart: P030x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P030x > Page 217 P0300 - P0304: Testing and Inspection P0300 For diagnosis of code P0300, refer to chart: P0300 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0310 - P0314, ( P0311 P0312 P0313 0310 0311 0312 0313 0314 ) > System Information > System Diagnosis P0310 - P0314: Testing and Inspection For diagnosis of code P0310, refer to chart: P0310 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0315 - P0319, ( P0316 P0317 P0318 0315 0316 0317 0318 0319 ) > System Information > System Diagnosis > P0315 P0315 - P0319: Testing and Inspection P0315 For diagnosis of code P0315, refer to chart: P0315 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0315 - P0319, ( P0316 P0317 P0318 0315 0316 0317 0318 0319 ) > System Information > System Diagnosis > P0315 > Page 225 P0315 - P0319: Testing and Inspection P0316 For diagnosis of code P0316, refer to chart: P0316 P0316 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0320 - P0324, ( P0321 P0322 P0323 0320 0321 0322 0323 0324 ) > System Information > System Diagnosis P0320 - P0324: Testing and Inspection For diagnosis of code P0320, refer to chart: P0320 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0325 - P0329, ( P0326 P0327 P0328 0325 0326 0327 0328 0329 ) > System Information > System Diagnosis > P0325 P0325 - P0329: Testing and Inspection P0325 For diagnosis of code P0325, refer to chart: P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0325 - P0329, ( P0326 P0327 P0328 0325 0326 0327 0328 0329 ) > System Information > System Diagnosis > P0325 > Page 233 P0325 - P0329: Testing and Inspection P0326 For diagnosis of code P0326, refer to chart: P0326 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0330 - P0334, ( P0331 P0332 P0333 0330 0331 0332 0333 0334 ) > System Information > System Diagnosis > P0330 P0330 - P0334: Testing and Inspection P0330 For diagnosis of code P0330, refer to chart: P0330 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0330 - P0334, ( P0331 P0332 P0333 0330 0331 0332 0333 0334 ) > System Information > System Diagnosis > P0330 > Page 238 P0330 - P0334: Testing and Inspection P0331 For diagnosis of code P0331, refer to chart: P0331 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0340 - P0344, ( P0341 P0342 P0343 0340 0341 0342 0343 0344 ) > System Information > System Diagnosis > P0340 P0340 - P0344: Testing and Inspection P0340 For diagnosis of code P0340, refer to chart: P0340 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0340 - P0344, ( P0341 P0342 P0343 0340 0341 0342 0343 0344 ) > System Information > System Diagnosis > P0340 > Page 243 P0340 - P0344: Testing and Inspection P0344 For diagnosis of code P0344, refer to chart: P0344 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0345 - P0349, ( P0346 P0347 P0348 0345 0346 0347 0348 0349 ) > System Information > System Diagnosis > P0345 P0345 - P0349: Testing and Inspection P0345 For diagnosis of code P0345, refer to chart: P0345 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0345 - P0349, ( P0346 P0347 P0348 0345 0346 0347 0348 0349 ) > System Information > System Diagnosis > P0345 > Page 248 P0345 - P0349: Testing and Inspection P0349 For diagnosis of code P0349, refer to chart: P0349 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 P0350 - P0354: Testing and Inspection P0350 For diagnosis of code P0350, refer to chart: P0350 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 253 P0350 - P0354: Testing and Inspection P0351 For diagnosis of code P0351, refer to chart: P0351 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 254 P0350 - P0354: Testing and Inspection P0352 For diagnosis of code P0352, refer to chart: P0352 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 255 P0350 - P0354: Testing and Inspection P0353 For diagnosis of code P0353, refer to chart: P0353 (Part 1) P0353 (Part 2) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 256 P0350 - P0354: Testing and Inspection P0354 For diagnosis of code P0354, refer to chart: P0354 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 P0355 - P0359: Testing and Inspection P0355 For diagnosis of code P0355, refer to chart: P0355 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 261 P0355 - P0359: Testing and Inspection P0356 For diagnosis of code P0356, refer to chart: P0356 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 262 P0355 - P0359: Testing and Inspection P0357 For diagnosis of code P0357, refer to chart: P0357 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 263 P0355 - P0359: Testing and Inspection P0358 For diagnosis of code P0358, refer to chart: P0358 (Part 1) P0358 (Part 2) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 264 P0355 - P0359: Testing and Inspection P0359 For diagnosis of code P0359, refer to chart: P0359 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0360 - P0364, ( P0361 P0362 P0363 0360 0361 0362 0363 0364 ) > System Information > System Diagnosis P0360 - P0364: Testing and Inspection For diagnosis of code P0360, refer to chart: P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 P0400 - P0404: Testing and Inspection P0400 For diagnosis of code P0400, refer to chart: P0400 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 273 P0400 - P0404: Testing and Inspection P0401 For diagnosis of code P0401, refer to chart: P0401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 274 P0400 - P0404: Testing and Inspection P0402 For diagnosis of code P0402, refer to chart: P0402 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 275 P0400 - P0404: Testing and Inspection P0403 For diagnosis of code P0403, refer to chart: P0403 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0405 - P0409, ( P0406 P0407 P0408 0405 0406 0407 0408 0409 ) > System Information > System Diagnosis > P0405 P0405 - P0409: Testing and Inspection P0405 For diagnosis of code P0405, refer to chart: P0405 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0405 - P0409, ( P0406 P0407 P0408 0405 0406 0407 0408 0409 ) > System Information > System Diagnosis > P0405 > Page 280 P0405 - P0409: Testing and Inspection P0406 For diagnosis of code P0406, refer to chart: P0406 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0410 - P0414, ( P0411 P0412 P0413 0410 0411 0412 0413 0414 ) > System Information > System Diagnosis > P0410 P0410 - P0414: Testing and Inspection P0410 For diagnosis of code P0410, refer to chart: P0410 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0410 - P0414, ( P0411 P0412 P0413 0410 0411 0412 0413 0414 ) > System Information > System Diagnosis > P0410 > Page 285 P0410 - P0414: Testing and Inspection P0412 For diagnosis of code P0412, refer to chart: P0412 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0420 - P0424, ( P0421 P0422 P0423 0420 0421 0422 0423 0424 ) > System Information > System Diagnosis P0420 - P0424: Testing and Inspection For diagnosis of code P0420, refer to chart: P0420 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0430 - P0434, ( P0431 P0432 P0433 0430 0431 0432 0433 0434 ) > System Information > System Diagnosis P0430 - P0434: Testing and Inspection For diagnosis of code P0430, refer to chart: P0430 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0440 - P0444, ( P0441 P0442 P0443 0440 0441 0442 0443 0444 ) > System Information > System Diagnosis > P0442 P0440 - P0444: Testing and Inspection P0442 For diagnosis of code P0442, refer to chart: P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0440 - P0444, ( P0441 P0442 P0443 0440 0441 0442 0443 0444 ) > System Information > System Diagnosis > P0442 > Page 296 P0440 - P0444: Testing and Inspection P0443 For diagnosis of code P0443, refer to chart: P0443 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0445 - P0449, ( P0446 P0447 P0448 0445 0446 0447 0448 0449 ) > System Information > System Diagnosis P0445 - P0449: Testing and Inspection For diagnosis of code P0446, refer to chart: P0446 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454, ( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 P0450 - P0454: Testing and Inspection P0451 For diagnosis of code P0451, refer to chart: P0451 (Part 1) P0451 (Part 2) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454, ( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 304 P0450 - P0454: Testing and Inspection P0452 For diagnosis of code P0452, refer to chart: P0452 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454, ( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 305 P0450 - P0454: Testing and Inspection P0453 For diagnosis of code P0453, refer to chart: P0453 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454, ( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 306 P0450 - P0454: Testing and Inspection P0454 For diagnosis of code P0454, refer to chart: P0454 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0455 - P0459, ( P0456 P0457 P0458 0455 0456 0457 0458 0459 ) > System Information > System Diagnosis > P0455 P0455 - P0459: Testing and Inspection P0455 For diagnosis of code P0455, refer to chart: P0455 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0455 - P0459, ( P0456 P0457 P0458 0455 0456 0457 0458 0459 ) > System Information > System Diagnosis > P0455 > Page 311 P0455 - P0459: Testing and Inspection P0456 For diagnosis of code P0456, refer to chart: P0456 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0455 - P0459, ( P0456 P0457 P0458 0455 0456 0457 0458 0459 ) > System Information > System Diagnosis > P0455 > Page 312 P0455 - P0459: Testing and Inspection P0457 For diagnosis of code P0457, refer to chart: P0457 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464, ( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460 P0460 - P0464: Testing and Inspection P0460 For diagnosis of code P0460, refer to chart: P0460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464, ( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460 > Page 317 P0460 - P0464: Testing and Inspection P0461 For diagnosis of code P0461, refer to chart: P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464, ( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460 > Page 318 P0460 - P0464: Testing and Inspection P0462 For diagnosis of code P0462, refer to chart: P0462 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464, ( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460 > Page 319 P0460 - P0464: Testing and Inspection P0463 For diagnosis of code P0463, refer to chart: P0463 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0480 - P0484, ( P0481 P0482 P0483 0480 0481 0482 0483 0484 ) > System Information > System Diagnosis > P0480 P0480 - P0484: Testing and Inspection P0480 For diagnosis of code P0480, refer to chart: P0480 (Part 1) P0480 (Part 2) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0480 - P0484, ( P0481 P0482 P0483 0480 0481 0482 0483 0484 ) > System Information > System Diagnosis > P0480 > Page 324 P0480 - P0484: Testing and Inspection P0481 For diagnosis of code P0481, refer to chart: P0481 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0480 - P0484, ( P0481 P0482 P0483 0480 0481 0482 0483 0484 ) > System Information > System Diagnosis > P0480 > Page 325 P0480 - P0484: Testing and Inspection P0482 For diagnosis of code P0482, refer to chart: P0482 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0480 - P0484, ( P0481 P0482 P0483 0480 0481 0482 0483 0484 ) > System Information > System Diagnosis > P0480 > Page 326 P0480 - P0484: Testing and Inspection P0483 For diagnosis of code P0483, refer to chart: P0483 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0490 - P0494, ( P0491 P0492 P0493 0490 0491 0492 0493 0494 ) > System Information > System Diagnosis P0490 - P0494: Testing and Inspection For diagnosis of code P0491, refer to chart: P0491 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 P0500 - P0504: Testing and Inspection P0500 For diagnosis of code P0500, refer to chart: P0500 (Part 1) P0500 (Part 2) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 > Page 335 P0500 - P0504: Testing and Inspection P0503 For diagnosis of code P0503, refer to chart: P0503 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0505 - P0509, ( P0506 P0507 P0508 0505 0506 0507 0508 0509 ) > System Information > System Diagnosis > P0505 P0505 - P0509: Testing and Inspection P0505 For diagnosis of code P0505, refer to chart: P0505 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0505 - P0509, ( P0506 P0507 P0508 0505 0506 0507 0508 0509 ) > System Information > System Diagnosis > P0505 > Page 340 P0505 - P0509: Testing and Inspection P0506 For diagnosis of code P0506, refer to chart: P0506 (Part 1) P0506 (Part 2) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0505 - P0509, ( P0506 P0507 P0508 0505 0506 0507 0508 0509 ) > System Information > System Diagnosis > P0505 > Page 341 P0505 - P0509: Testing and Inspection P0507 For diagnosis of code P0507, refer to chart: P0507 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P050A - P050E, ( P050B P050C P050D 050A 050B 050C 050D 050E ) > System Information > System Diagnosis > P050A P050A - P050E: Testing and Inspection P050A For diagnosis of code P050A, refer to chart: P050A If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P050A - P050E, ( P050B P050C P050D 050A 050B 050C 050D 050E ) > System Information > System Diagnosis > P050A > Page 346 P050A - P050E: Testing and Inspection P050B For diagnosis of code P050B, refer to chart: P050B If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0510 - P0514, ( P0511 P0512 P0513 0510 0511 0512 0513 0514 ) > System Information > System Diagnosis P0510 - P0514: Testing and Inspection For diagnosis of code P0511, refer to chart: P0511 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0525 - P0529, ( P0526 P0527 P0528 0525 0526 0527 0528 0529 ) > System Information > System Diagnosis P0525 - P0529: Testing and Inspection For diagnosis of code P0528, refer to chart: P0528 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0530 - P0534, ( P0531 P0532 P0533 0530 0531 0532 0533 0534 ) > System Information > System Diagnosis > P0532 P0530 - P0534: Testing and Inspection P0532 For diagnosis of code P0532, refer to chart: P0532 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0530 - P0534, ( P0531 P0532 P0533 0530 0531 0532 0533 0534 ) > System Information > System Diagnosis > P0532 > Page 357 P0530 - P0534: Testing and Inspection P0533 For diagnosis of code P0533, refer to chart: P0533 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0530 - P0534, ( P0531 P0532 P0533 0530 0531 0532 0533 0534 ) > System Information > System Diagnosis > P0532 > Page 358 P0530 - P0534: Testing and Inspection P0534 For diagnosis of code P0534, refer to chart: P0534 (Part 1) P0534 (Part 2) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0535 - P0539, ( P0536 P0537 P0538 0535 0536 0537 0538 0539 ) > System Information > System Diagnosis > P0537 P0535 - P0539: Testing and Inspection P0537 For diagnosis of code P0537, refer to chart: P0537 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0535 - P0539, ( P0536 P0537 P0538 0535 0536 0537 0538 0539 ) > System Information > System Diagnosis > P0537 > Page 363 P0535 - P0539: Testing and Inspection P0538 For diagnosis of code P0538, refer to chart: P0538 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0550 - P0554, ( P0551 P0552 P0553 0550 0551 0552 0553 0554 ) > System Information > System Diagnosis > P0552 P0550 - P0554: Testing and Inspection P0552 For diagnosis of code P0552, refer to chart: P0552 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0550 - P0554, ( P0551 P0552 P0553 0550 0551 0552 0553 0554 ) > System Information > System Diagnosis > P0552 > Page 368 P0550 - P0554: Testing and Inspection P0553 For diagnosis of code P0553, refer to chart: P0553 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0575 - P0579, ( P0576 P0577 P0578 0575 0576 0577 0578 0579 ) > System Information > System Diagnosis P0575 - P0579: Testing and Inspection For diagnosis of code P0579, refer to chart: P0579 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0580 - P0584, ( P0581 P0582 P0583 0580 0581 0582 0583 0584 ) > System Information > System Diagnosis P0580 - P0584: Testing and Inspection For diagnosis of code P0581, refer to chart: P0581 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604, ( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0600 P0600 - P0604: Testing and Inspection P0600 For diagnosis of code P0600, refer to chart: P0600 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604, ( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0600 > Page 380 P0600 - P0604: Testing and Inspection P0602 For diagnosis of code P0602, refer to chart: P0602 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604, ( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0600 > Page 381 P0600 - P0604: Testing and Inspection P0603 For diagnosis of code P0603, refer to chart: P0603 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604, ( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0600 > Page 382 P0600 - P0604: Testing and Inspection P0604 For diagnosis of code P0604, refer to chart: P0604 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0605 - P0609, ( P0606 P0607 P0608 0605 0606 0607 0608 0609 ) > System Information > System Diagnosis > P0605 P0605 - P0609: Testing and Inspection P0605 For diagnosis of code P0605, refer to chart: P0605 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0605 - P0609, ( P0606 P0607 P0608 0605 0606 0607 0608 0609 ) > System Information > System Diagnosis > P0605 > Page 387 P0605 - P0609: Testing and Inspection P0606 For diagnosis of code P0606, refer to chart: P0606 (Part 1) P0606 (Part 2) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0605 - P0609, ( P0606 P0607 P0608 0605 0606 0607 0608 0609 ) > System Information > System Diagnosis > P0605 > Page 388 P0605 - P0609: Testing and Inspection P0607 For diagnosis of code P0607, refer to chart: P0607 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P060A - P060E, ( P060B P060C P060D 060A 060B 060C 060D 060E ) > System Information > System Diagnosis > P060A P060A - P060E: Testing and Inspection P060A For diagnosis of code P060A, refer to chart: P060A If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P060A - P060E, ( P060B P060C P060D 060A 060B 060C 060D 060E ) > System Information > System Diagnosis > P060A > Page 393 P060A - P060E: Testing and Inspection P060B For diagnosis of code P060B, refer to chart: P060B If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P060A - P060E, ( P060B P060C P060D 060A 060B 060C 060D 060E ) > System Information > System Diagnosis > P060A > Page 394 P060A - P060E: Testing and Inspection P060C For diagnosis of code P060C, refer to chart: P060C (Part 1) P060C (Part 2) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0610 - P0614, ( P0611 P0612 P0613 0610 0611 0612 0613 0614 ) > System Information > System Diagnosis P0610 - P0614: Testing and Inspection For diagnosis of code P0611, refer to chart: P0611 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P061A - P061E, ( P061B P061C P061D 061A 061B 061C 061D 061E ) > System Information > System Diagnosis > P061B P061A - P061E: Testing and Inspection P061B For diagnosis of code P061B, refer to chart: P061B If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P061A - P061E, ( P061B P061C P061D 061A 061B 061C 061D 061E ) > System Information > System Diagnosis > P061B > Page 402 P061A - P061E: Testing and Inspection P061C For diagnosis of code P061C, refer to chart: P061C If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P061A - P061E, ( P061B P061C P061D 061A 061B 061C 061D 061E ) > System Information > System Diagnosis > P061B > Page 403 P061A - P061E: Testing and Inspection P061D For diagnosis of code P061D, refer to chart: P061D If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P061F - P061J, ( P061G P061H P061I 061F 061G 061H 061I 061J ) > System Information > System Diagnosis P061F - P061J: Testing and Inspection For diagnosis of code P061F, refer to chart: P061F If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0620 - P0624, ( P0621 P0622 P0623 0620 0621 0622 0623 0624 ) > System Information > System Diagnosis > P0620 P0620 - P0624: Testing and Inspection P0620 For diagnosis of code P0620, refer to chart: P0620 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0620 - P0624, ( P0621 P0622 P0623 0620 0621 0622 0623 0624 ) > System Information > System Diagnosis > P0620 > Page 411 P0620 - P0624: Testing and Inspection P0622 For diagnosis of code P0622, refer to chart: P0622 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0625 - P0629, ( P0626 P0627 P0628 0625 0626 0627 0628 0629 ) > System Information > System Diagnosis > P0625 P0625 - P0629: Testing and Inspection P0625 For diagnosis of code P0625, refer to chart: P0625 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0625 - P0629, ( P0626 P0627 P0628 0625 0626 0627 0628 0629 ) > System Information > System Diagnosis > P0625 > Page 416 P0625 - P0629: Testing and Inspection P0626 For diagnosis of code P0626, refer to chart: P0626 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P062A - P062E, ( P062B P062C P062D 062A 062B 062C 062D 062E ) > System Information > System Diagnosis P062A - P062E: Testing and Inspection For diagnosis of code P062C, refer to chart: P062C If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0645 - P0649, ( P0646 P0647 P0648 0645 0646 0647 0648 0649 ) > System Information > System Diagnosis P0645 - P0649: Testing and Inspection For diagnosis of code P0645, refer to chart: P0645 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0655 - P0659, ( P0656 P0657 P0658 0655 0656 0657 0658 0659 ) > System Information > System Diagnosis P0655 - P0659: Testing and Inspection For diagnosis of code P0657, refer to chart: P0657 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0660 - P0664, ( P0661 P0662 P0663 0660 0661 0662 0663 0664 ) > System Information > System Diagnosis P0660 - P0664: Testing and Inspection For diagnosis of code P0660, refer to chart: P0660 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0685 - P0689, ( P0686 P0687 P0688 0685 0686 0687 0688 0689 ) > System Information > System Diagnosis > P0685 P0685 - P0689: Testing and Inspection P0685 For diagnosis of code P0685, refer to chart: P0685 (Part 1) P0685 (Part 2) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0685 - P0689, ( P0686 P0687 P0688 0685 0686 0687 0688 0689 ) > System Information > System Diagnosis > P0685 > Page 433 P0685 - P0689: Testing and Inspection P0689 For diagnosis of code P0689, refer to chart: P0689 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0690 - P0694, ( P0691 P0692 P0693 0690 0691 0692 0693 0694 ) > System Information > System Diagnosis P0690 - P0694: Testing and Inspection For diagnosis of code P0690, refer to chart: P0690 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0700 - P0704, ( P0701 P0702 P0703 0700 0701 0702 0703 0704 ) > System Information > System Diagnosis > P0703 P0700 - P0704: Testing and Inspection P0703 For diagnosis of code P0703, refer to chart: P0703 (Part 1) P0703 (Part 2) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0700 - P0704, ( P0701 P0702 P0703 0700 0701 0702 0703 0704 ) > System Information > System Diagnosis > P0703 > Page 442 P0700 - P0704: Testing and Inspection P0704 For diagnosis of code P0704, refer to chart: P0704 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 P0705 - P0709: Testing and Inspection P0705 For diagnosis of code P0705, refer to chart: P0705 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 > Page 447 P0705 - P0709: Testing and Inspection P0707 For diagnosis of code P0707, refer to chart: P0707 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 > Page 448 P0705 - P0709: Testing and Inspection P0708 For diagnosis of code P0708, refer to chart: P0708 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714, ( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis P0710 - P0714: Testing and Inspection For diagnosis of code P071X, refer to chart: P071x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 P0720 - P0724: Testing and Inspection P0720 For diagnosis of code P0720, refer to chart: P0720 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 > Page 456 P0720 - P0724: Testing and Inspection P0721 For diagnosis of code P0721, refer to chart: P0721 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 > Page 457 P0720 - P0724: Testing and Inspection P0722 For diagnosis of code P0722, refer to chart: P0722 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 > Page 458 P0720 - P0724: Testing and Inspection P0723 For diagnosis of code P0723, refer to chart: P0723 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734, ( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis P0730 - P0734: Testing and Inspection For diagnosis of code P073X, refer to chart: P073x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744, ( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis P0740 - P0744: Testing and Inspection For diagnosis of code P074X, refer to chart: P074x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0750 - P0754, ( P0751 P0752 P0753 0750 0751 0752 0753 0754 ) > System Information > System Diagnosis P0750 - P0754: Testing and Inspection For diagnosis of code P075X, refer to chart: P075x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0760 - P0764, ( P0761 P0762 P0763 0760 0761 0762 0763 0764 ) > System Information > System Diagnosis P0760 - P0764: Testing and Inspection For diagnosis of code P076X, refer to chart: P076x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0770 - P0774, ( P0771 P0772 P0773 0770 0771 0772 0773 0774 ) > System Information > System Diagnosis P0770 - P0774: Testing and Inspection For diagnosis of code P077X, refer to chart: P077x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0780 - P0784, ( P0781 P0782 P0783 0780 0781 0782 0783 0784 ) > System Information > System Diagnosis P0780 - P0784: Testing and Inspection For diagnosis of code P078X, refer to chart: P078x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0790 - P0794, ( P0791 P0792 P0793 0790 0791 0792 0793 0794 ) > System Information > System Diagnosis P0790 - P0794: Testing and Inspection For diagnosis of code P079X, refer to chart: P079x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0800-P08ZZ > P0815 - P0819, ( P0816 P0817 P0818 0815 0816 0817 0818 0819 ) > System Information > System Diagnosis P0815 - P0819: Testing and Inspection For diagnosis of code P0815, refer to chart: P0815 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0800-P08ZZ > P0830 - P0834, ( P0831 P0832 P0833 0830 0831 0832 0833 0834 ) > System Information > System Diagnosis > P0830 P0830 - P0834: Testing and Inspection P0830 For diagnosis of code P0830, refer to chart: P0830 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0800-P08ZZ > P0830 - P0834, ( P0831 P0832 P0833 0830 0831 0832 0833 0834 ) > System Information > System Diagnosis > P0830 > Page 488 P0830 - P0834: Testing and Inspection P0833 For diagnosis of code P0833, refer to chart: P0833 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0800-P08ZZ > P0840 - P0844, ( P0841 P0842 P0843 0840 0841 0842 0843 0844 ) > System Information > System Diagnosis P0840 - P0844: Testing and Inspection For diagnosis of code P0840, refer to chart: P0840 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0900-P09ZZ > P0900 - P0904, ( P0901 P0902 P0903 0900 0901 0902 0903 0904 ) > System Information > System Diagnosis P0900 - P0904: Testing and Inspection For diagnosis of code P09XX, refer to chart: P09xx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1000-P10ZZ > P1000 - P1004, ( P1001 P1002 P1003 1000 1001 1002 1003 1004 ) > System Information > System Diagnosis > P1000 P1000 - P1004: Testing and Inspection P1000 For diagnosis of code P1000, refer to chart: P1000 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1000-P10ZZ > P1000 - P1004, ( P1001 P1002 P1003 1000 1001 1002 1003 1004 ) > System Information > System Diagnosis > P1000 > Page 501 P1000 - P1004: Testing and Inspection P1001 For diagnosis of code P1001, refer to chart: P1001 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1100 - P1104, ( P1101 P1102 P1103 1100 1101 1102 1103 1104 ) > System Information > System Diagnosis > P1100 P1100 - P1104: Testing and Inspection P1100 For diagnosis of code P1100, refer to chart: P1100 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1100 - P1104, ( P1101 P1102 P1103 1100 1101 1102 1103 1104 ) > System Information > System Diagnosis > P1100 > Page 507 P1100 - P1104: Testing and Inspection P1101 For diagnosis of code P1101, refer to chart: P1101 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1110 - P1114, ( P1111 P1112 P1113 1110 1111 1112 1113 1114 ) > System Information > System Diagnosis > P1112 P1110 - P1114: Testing and Inspection P1112 For diagnosis of code P1112, refer to chart: P1112 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1110 - P1114, ( P1111 P1112 P1113 1110 1111 1112 1113 1114 ) > System Information > System Diagnosis > P1112 > Page 512 P1110 - P1114: Testing and Inspection P1114 For diagnosis of code P1114, refer to chart: P1114 (Part 1) P1114 (Part 2) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119, ( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1115 P1115 - P1119: Testing and Inspection P1115 For diagnosis of code P1115, refer to chart: P1115 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119, ( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1115 > Page 517 P1115 - P1119: Testing and Inspection P1116 For diagnosis of code P1116, refer to chart: P1116 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119, ( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1115 > Page 518 P1115 - P1119: Testing and Inspection P1117 For diagnosis of code P1117, refer to chart: P1117 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124, ( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 P1120 - P1124: Testing and Inspection P1120 For diagnosis of code P1120, refer to chart: P1120 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124, ( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 > Page 523 P1120 - P1124: Testing and Inspection P1124 For diagnosis of code P1124, refer to chart: P1124 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 P1125 - P1129: Testing and Inspection P1125 For diagnosis of code P1125, refer to chart: P1125 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 528 P1125 - P1129: Testing and Inspection P1127 For diagnosis of code P1127, refer to chart: P1127 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1155 - P1159, ( P1156 P1157 P1158 1155 1156 1157 1158 1159 ) > System Information > System Diagnosis P1155 - P1159: Testing and Inspection For diagnosis of code P1156, refer to chart: P1156 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P117A - P117E, ( P117B P117C P117D 117A 117B 117C 117D 117E ) > System Information > System Diagnosis P117A - P117E: Testing and Inspection For diagnosis of code P117A, refer to chart: If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184, ( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis P1180 - P1184: Testing and Inspection For diagnosis of code P1184, refer to chart: P1184 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1225 - P1229, ( P1226 P1227 P1228 1225 1226 1227 1228 1229 ) > System Information > System Diagnosis P1225 - P1229: Testing and Inspection For diagnosis of code P1229, refer to chart: P1229 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234, ( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1233 P1230 - P1234: Testing and Inspection P1233 For diagnosis of code P1233, refer to chart: P1233 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234, ( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1233 > Page 546 P1230 - P1234: Testing and Inspection P1234 For diagnosis of code P1234, refer to chart: P1234 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 P1235 - P1239: Testing and Inspection P1235 For diagnosis of code P1235, refer to chart: P1235 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 551 P1235 - P1239: Testing and Inspection P1236 For diagnosis of code P1236, refer to chart: P1236 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 552 P1235 - P1239: Testing and Inspection P1237 For diagnosis of code P1237, refer to chart: P1237 (Part 1) P1237 (Part 2) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 553 P1235 - P1239: Testing and Inspection P1238 For diagnosis of code P1238, refer to chart: P1238 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1240 - P1244, ( P1241 P1242 P1243 1240 1241 1242 1243 1244 ) > System Information > System Diagnosis P1240 - P1244: Testing and Inspection For diagnosis of code P1244, refer to chart: P1244 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1245 - P1249, ( P1246 P1247 P1248 1245 1246 1247 1248 1249 ) > System Information > System Diagnosis > P1245 P1245 - P1249: Testing and Inspection P1245 For diagnosis of code P1245, refer to chart: P1245 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1245 - P1249, ( P1246 P1247 P1248 1245 1246 1247 1248 1249 ) > System Information > System Diagnosis > P1245 > Page 561 P1245 - P1249: Testing and Inspection P1246 For diagnosis of code P1246, refer to chart: P1246 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1260 - P1264, ( P1261 P1262 P1263 1260 1261 1262 1263 1264 ) > System Information > System Diagnosis > P1260 P1260 - P1264: Testing and Inspection P1260 For diagnosis of code P1260, refer to chart: P1260 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1260 - P1264, ( P1261 P1262 P1263 1260 1261 1262 1263 1264 ) > System Information > System Diagnosis > P1260 > Page 566 P1260 - P1264: Testing and Inspection P1261 For diagnosis of code P1261, refer to chart: P1261 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1260 - P1264, ( P1261 P1262 P1263 1260 1261 1262 1263 1264 ) > System Information > System Diagnosis > P1260 > Page 567 P1260 - P1264: Testing and Inspection P1262 For diagnosis of code P1262, refer to chart: P1262 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1260 - P1264, ( P1261 P1262 P1263 1260 1261 1262 1263 1264 ) > System Information > System Diagnosis > P1260 > Page 568 P1260 - P1264: Testing and Inspection P1263 For diagnosis of code P1263, refer to chart: P1263 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1260 - P1264, ( P1261 P1262 P1263 1260 1261 1262 1263 1264 ) > System Information > System Diagnosis > P1260 > Page 569 P1260 - P1264: Testing and Inspection P1264 For diagnosis of code P1264, refer to chart: P1264 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1265 - P1269, ( P1266 P1267 P1268 1265 1266 1267 1268 1269 ) > System Information > System Diagnosis > P1265 P1265 - P1269: Testing and Inspection P1265 For diagnosis of code P1265, refer to chart: P1265 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1265 - P1269, ( P1266 P1267 P1268 1265 1266 1267 1268 1269 ) > System Information > System Diagnosis > P1265 > Page 574 P1265 - P1269: Testing and Inspection P1266 For diagnosis of code P1266, refer to chart: P1266 (Part 1) P1266 (Part 2) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1265 - P1269, ( P1266 P1267 P1268 1265 1266 1267 1268 1269 ) > System Information > System Diagnosis > P1265 > Page 575 P1265 - P1269: Testing and Inspection P1267 For diagnosis of code P1267, refer to chart: P1267 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1265 - P1269, ( P1266 P1267 P1268 1265 1266 1267 1268 1269 ) > System Information > System Diagnosis > P1265 > Page 576 P1265 - P1269: Testing and Inspection P1268 For diagnosis of code P1268, refer to chart: P1268 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1270 - P1274, ( P1271 P1272 P1273 1270 1271 1272 1273 1274 ) > System Information > System Diagnosis > P1270 P1270 - P1274: Testing and Inspection P1270 For diagnosis of code P1270, refer to chart: P1270 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1270 - P1274, ( P1271 P1272 P1273 1270 1271 1272 1273 1274 ) > System Information > System Diagnosis > P1270 > Page 581 P1270 - P1274: Testing and Inspection P1271 For diagnosis of code P1271, refer to chart: P1271 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1270 - P1274, ( P1271 P1272 P1273 1270 1271 1272 1273 1274 ) > System Information > System Diagnosis > P1270 > Page 582 P1270 - P1274: Testing and Inspection P1272 For diagnosis of code P1272, refer to chart: P1272 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1270 - P1274, ( P1271 P1272 P1273 1270 1271 1272 1273 1274 ) > System Information > System Diagnosis > P1270 > Page 583 P1270 - P1274: Testing and Inspection P1273 For diagnosis of code P1273, refer to chart: P1273 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1270 - P1274, ( P1271 P1272 P1273 1270 1271 1272 1273 1274 ) > System Information > System Diagnosis > P1270 > Page 584 P1270 - P1274: Testing and Inspection P1274 For diagnosis of code P1274, refer to chart: P1274 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1275 - P1279, ( P1276 P1277 P1278 1275 1276 1277 1278 1279 ) > System Information > System Diagnosis > P1275 P1275 - P1279: Testing and Inspection P1275 For diagnosis of code P1275, refer to chart: P1275 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1275 - P1279, ( P1276 P1277 P1278 1275 1276 1277 1278 1279 ) > System Information > System Diagnosis > P1275 > Page 589 P1275 - P1279: Testing and Inspection P1276 For diagnosis of code P1276, refer to chart: P1276 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1275 - P1279, ( P1276 P1277 P1278 1275 1276 1277 1278 1279 ) > System Information > System Diagnosis > P1275 > Page 590 P1275 - P1279: Testing and Inspection P1277 For diagnosis of code P1277, refer to chart: P1277 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1275 - P1279, ( P1276 P1277 P1278 1275 1276 1277 1278 1279 ) > System Information > System Diagnosis > P1275 > Page 591 P1275 - P1279: Testing and Inspection P1278 For diagnosis of code P1278, refer to chart: P1278 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289, ( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 P1285 - P1289: Testing and Inspection P1285 For diagnosis of code P1285, refer to chart: P1285 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link:See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289, ( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 596 P1285 - P1289: Testing and Inspection P1288 For diagnosis of code P1288, refer to chart: P1288 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289, ( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 597 P1285 - P1289: Testing and Inspection P1289 For diagnosis of code P1289, refer to chart: P1289 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P128A - P128E, ( P128B P128C P128D 128A 128B 128C 128D 128E ) > System Information > System Diagnosis P128A - P128E: Testing and Inspection For diagnosis of code P128A, refer to chart: P128A If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1290 - P1294, ( P1291 P1292 P1293 1290 1291 1292 1293 1294 ) > System Information > System Diagnosis P1290 - P1294: Testing and Inspection For diagnosis of code P1290, refer to chart: P1290 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1295 - P1299, ( P1296 P1297 P1298 1295 1296 1297 1298 1299 ) > System Information > System Diagnosis P1295 - P1299: Testing and Inspection For diagnosis of code P1299, refer to chart: P1299 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1305 - P1309, ( P1306 P1307 P1308 1305 1306 1307 1308 1309 ) > System Information > System Diagnosis P1305 - P1309: Testing and Inspection For diagnosis of code P1309, refer to chart: P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1335 - P1339, ( P1336 P1337 P1338 1335 1336 1337 1338 1339 ) > System Information > System Diagnosis P1335 - P1339: Testing and Inspection For diagnosis of code P1336, refer to chart: P1336 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1395 - P1399, ( P1396 P1397 P1398 1395 1396 1397 1398 1399 ) > System Information > System Diagnosis P1395 - P1399: Testing and Inspection For diagnosis of code P1397, refer to chart: P1397 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 P1405 - P1409: Testing and Inspection P1405 For diagnosis of code P1405, refer to chart: P1405 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 622 P1405 - P1409: Testing and Inspection P1406 For diagnosis of code P1406, refer to chart: P1406 (Part 1) P1406 (Part 2) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link:See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 623 P1405 - P1409: Testing and Inspection P1408 For diagnosis of code P1408, refer to chart: P1408 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 624 P1405 - P1409: Testing and Inspection P1409 For diagnosis of code P1409, refer to chart: P1409 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1435 - P1439, ( P1436 P1437 P1438 1435 1436 1437 1438 1439 ) > System Information > System Diagnosis > P1436 P1435 - P1439: Testing and Inspection P1436 For diagnosis of code P1436, refer to chart: P1436 (Part 1) P1436 (Part 2) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1435 - P1439, ( P1436 P1437 P1438 1435 1436 1437 1438 1439 ) > System Information > System Diagnosis > P1436 > Page 629 P1435 - P1439: Testing and Inspection P1437 For diagnosis of code P1437, refer to chart: P1437 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1440 - P1444, ( P1441 P1442 P1443 1440 1441 1442 1443 1444 ) > System Information > System Diagnosis P1440 - P1444: Testing and Inspection For diagnosis of code P1443, refer to chart: P1443 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1450 - P1454, ( P1451 P1452 P1453 1450 1451 1452 1453 1454 ) > System Information > System Diagnosis > P1450 P1450 - P1454: Testing and Inspection P1450 For diagnosis of code P1450, refer to chart: P1450 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1450 - P1454, ( P1451 P1452 P1453 1450 1451 1452 1453 1454 ) > System Information > System Diagnosis > P1450 > Page 637 P1450 - P1454: Testing and Inspection P1451 For diagnosis of code P1451, refer to chart: P1451 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 P1460 - P1464: Testing and Inspection P1460 For diagnosis of code P1460, refer to chart: P1460 (Part 1) P1460 (Part 2) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 642 P1460 - P1464: Testing and Inspection P1461 For diagnosis of code P1461, refer to chart: P1461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 643 P1460 - P1464: Testing and Inspection P1462 For diagnosis of code P1462, refer to chart: P1462 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 644 P1460 - P1464: Testing and Inspection P1463 For diagnosis of code P1463, refer to chart: P1463 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 645 P1460 - P1464: Testing and Inspection P1464 For diagnosis of code P1464, refer to chart: P1464 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1465 - P1469, ( P1466 P1467 P1468 1465 1466 1467 1468 1469 ) > System Information > System Diagnosis P1465 - P1469: Testing and Inspection For diagnosis of code P1469, refer to chart: P1469 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1470 - P1474, ( P1471 P1472 P1473 1470 1471 1472 1473 1474 ) > System Information > System Diagnosis P1470 - P1474: Testing and Inspection For diagnosis of code P1474, refer to chart: P1474 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1475 - P1479, ( P1476 P1477 P1478 1475 1476 1477 1478 1479 ) > System Information > System Diagnosis > P1477 P1475 - P1479: Testing and Inspection P1477 For diagnosis of code P1477, refer to chart: P1477 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1475 - P1479, ( P1476 P1477 P1478 1475 1476 1477 1478 1479 ) > System Information > System Diagnosis > P1477 > Page 656 P1475 - P1479: Testing and Inspection P1479 For diagnosis of code P1479, refer to chart: P1479 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1485 - P1489, ( P1486 P1487 P1488 1485 1486 1487 1488 1489 ) > System Information > System Diagnosis P1485 - P1489: Testing and Inspection For diagnosis of code P1489, refer to chart: P1489 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 P1500 - P1504: Testing and Inspection P1500 For diagnosis of code P1500, refer to chart: P1500 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 665 P1500 - P1504: Testing and Inspection P1501 For diagnosis of code P1501, refer to chart: P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 666 P1500 - P1504: Testing and Inspection P1502 For diagnosis of code P1502, refer to chart: P1502 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 667 P1500 - P1504: Testing and Inspection P1504 For diagnosis of code P1504, refer to chart: P1504 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1505 - P1509, ( P1506 P1507 P1508 1505 1506 1507 1508 1509 ) > System Information > System Diagnosis > P1506 P1505 - P1509: Testing and Inspection P1506 For diagnosis of code P1506, refer to chart: P1506 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1505 - P1509, ( P1506 P1507 P1508 1505 1506 1507 1508 1509 ) > System Information > System Diagnosis > P1506 > Page 672 P1505 - P1509: Testing and Inspection P1507 For diagnosis of code P1507, refer to chart: P1507 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1510 - P1514, ( P1511 P1512 P1513 1510 1511 1512 1513 1514 ) > System Information > System Diagnosis > P1512 P1510 - P1514: Testing and Inspection P1512 For diagnosis of code P1512, refer to chart: P1512 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1510 - P1514, ( P1511 P1512 P1513 1510 1511 1512 1513 1514 ) > System Information > System Diagnosis > P1512 > Page 677 P1510 - P1514: Testing and Inspection P1513 For diagnosis of code P1513, refer to chart: P1513 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 P1515 - P1519: Testing and Inspection P1516 For diagnosis of code P1516, refer to chart: P1516 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 682 P1515 - P1519: Testing and Inspection P1517 For diagnosis of code P1517, refer to chart: P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 683 P1515 - P1519: Testing and Inspection P1518 For diagnosis of code P1518, refer to chart: P1518 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 684 P1515 - P1519: Testing and Inspection P1519 For diagnosis of code P1519, refer to chart: P1519 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P151A - P151E, ( P151B P151C P151D 151A 151B 151C 151D 151E ) > System Information > System Diagnosis P151A - P151E: Testing and Inspection For diagnosis of code P151A, refer to chart: P151A If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1520 - P1524, ( P1521 P1522 P1523 1520 1521 1522 1523 1524 ) > System Information > System Diagnosis P1520 - P1524: Testing and Inspection For diagnosis of code P1520, refer to chart: P1520 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1535 - P1539, ( P1536 P1537 P1538 1535 1536 1537 1538 1539 ) > System Information > System Diagnosis > P1537 P1535 - P1539: Testing and Inspection P1537 For diagnosis of code P1537, refer to chart: P1537 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1535 - P1539, ( P1536 P1537 P1538 1535 1536 1537 1538 1539 ) > System Information > System Diagnosis > P1537 > Page 695 P1535 - P1539: Testing and Inspection P1538 For diagnosis of code P1538, refer to chart: P1538 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1545 - P1549, ( P1546 P1547 P1548 1545 1546 1547 1548 1549 ) > System Information > System Diagnosis P1545 - P1549: Testing and Inspection For diagnosis of code P1549, refer to chart: P1549 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1550 - P1554, ( P1551 P1552 P1553 1550 1551 1552 1553 1554 ) > System Information > System Diagnosis P1550 - P1554: Testing and Inspection For diagnosis of code P1550, refer to chart: P1550 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1565 - P1569, ( P1566 P1567 P1568 1565 1566 1567 1568 1569 ) > System Information > System Diagnosis > P1565 P1565 - P1569: Testing and Inspection P1565 For diagnosis of code P1565, refer to chart: P1565 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1565 - P1569, ( P1566 P1567 P1568 1565 1566 1567 1568 1569 ) > System Information > System Diagnosis > P1565 > Page 706 P1565 - P1569: Testing and Inspection P1566 For diagnosis of code P1566, refer to chart: P1566 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1565 - P1569, ( P1566 P1567 P1568 1565 1566 1567 1568 1569 ) > System Information > System Diagnosis > P1565 > Page 707 P1565 - P1569: Testing and Inspection P1567 For diagnosis of code P1567, refer to chart: P1567 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1565 - P1569, ( P1566 P1567 P1568 1565 1566 1567 1568 1569 ) > System Information > System Diagnosis > P1565 > Page 708 P1565 - P1569: Testing and Inspection P1568 For diagnosis of code P1568, refer to chart: P1568 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1570 - P1574, ( P1571 P1572 P1573 1570 1571 1572 1573 1574 ) > System Information > System Diagnosis P1570 - P1574: Testing and Inspection For diagnosis of code P1572, refer to chart: P1572 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1580 - P1584, ( P1581 P1582 P1583 1580 1581 1582 1583 1584 ) > System Information > System Diagnosis P1580 - P1584: Testing and Inspection For diagnosis of code P1582, refer to chart: P1582 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1630 - P1634, ( P1631 P1632 P1633 1630 1631 1632 1633 1634 ) > System Information > System Diagnosis P1630 - P1634: Testing and Inspection For diagnosis of code P1633, refer to chart: P1633 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 P1635 - P1639: Testing and Inspection P1635 For diagnosis of code P1635, refer to chart: P1635 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 723 P1635 - P1639: Testing and Inspection P1636 For diagnosis of code P1636, refer to chart: P1636 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 724 P1635 - P1639: Testing and Inspection P1639 For diagnosis of code P1639, refer to chart: P1639 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1640 - P1644, ( P1641 P1642 P1643 1640 1641 1642 1643 1644 ) > System Information > System Diagnosis > P1640 P1640 - P1644: Testing and Inspection P1640 For diagnosis of code P1640, refer to chart: P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1640 - P1644, ( P1641 P1642 P1643 1640 1641 1642 1643 1644 ) > System Information > System Diagnosis > P1640 > Page 729 P1640 - P1644: Testing and Inspection P1641 For diagnosis of code P1641, refer to chart: P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1650 - P1654, ( P1651 P1652 P1653 1650 1651 1652 1653 1654 ) > System Information > System Diagnosis > P1650 P1650 - P1654: Testing and Inspection P1650 For diagnosis of code P1650, refer to chart: P1650 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1650 - P1654, ( P1651 P1652 P1653 1650 1651 1652 1653 1654 ) > System Information > System Diagnosis > P1650 > Page 734 P1650 - P1654: Testing and Inspection P1651 For diagnosis of code P1651, refer to chart: P1651 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1670 - P1674, ( P1671 P1672 P1673 1670 1671 1672 1673 1674 ) > System Information > System Diagnosis P1670 - P1674: Testing and Inspection For diagnosis of code P1674, refer to chart: P1674 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P17xx P1700 - P1704: Testing and Inspection P17xx For diagnosis of code P17XX, refer to chart: P17xx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P17xx > Page 743 P1700 - P1704: Testing and Inspection P1703 For diagnosis of code P1703, refer to chart: P1703 (Part 1) P1703 (Part 2) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709, ( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 P1705 - P1709: Testing and Inspection P1705 For diagnosis of code P1705, refer to chart: P1705 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709, ( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 > Page 748 P1705 - P1709: Testing and Inspection P1709 For diagnosis of code P1709, refer to chart: P1709 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1725 - P1729, ( P1726 P1727 P1728 1725 1726 1727 1728 1729 ) > System Information > System Diagnosis P1725 - P1729: Testing and Inspection For diagnosis of code P1729, refer to chart: P1729 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 P1780 - P1784: Testing and Inspection P1780 For diagnosis of code P1780, refer to chart: P1780 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 756 P1780 - P1784: Testing and Inspection P1781 For diagnosis of code P1781, refer to chart: P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1800 - P1804, ( P1801 P1802 P1803 1800 1801 1802 1803 1804 ) > System Information > System Diagnosis P1800 - P1804: Testing and Inspection For diagnosis of code P18XX, refer to chart: P18xx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1810 - P1814, ( P1811 P1812 P1813 1810 1811 1812 1813 1814 ) > System Information > System Diagnosis P1810 - P1814: Testing and Inspection For diagnosis of code P1812, refer to chart: 4X4 Module (PCM) Diagnostic Trouble Code (DTC) Index (Part 1) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case system, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1815 - P1819, ( P1816 P1817 P1818 1815 1816 1817 1818 1819 ) > System Information > System Diagnosis P1815 - P1819: Testing and Inspection For diagnosis of code P1815, refer to chart: 4X4 Module (PCM) Diagnostic Trouble Code (DTC) Index (Part 1) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case system, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1820 - P1824, ( P1821 P1822 P1823 1820 1821 1822 1823 1824 ) > System Information > System Diagnosis > P1820 P1820 - P1824: Testing and Inspection P1820 For diagnosis of code P1820, refer to chart: 4X4 Module (PCM) Diagnostic Trouble Code (DTC) Index (Part 1) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case system, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1820 - P1824, ( P1821 P1822 P1823 1820 1821 1822 1823 1824 ) > System Information > System Diagnosis > P1820 > Page 771 P1820 - P1824: Testing and Inspection P1822 For diagnosis of code P1822, refer to chart: 4X4 Module (PCM) Diagnostic Trouble Code (DTC) Index (Part 1) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case system, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1820 - P1824, ( P1821 P1822 P1823 1820 1821 1822 1823 1824 ) > System Information > System Diagnosis > P1820 > Page 772 P1820 - P1824: Testing and Inspection P1824 For diagnosis of code P1824, refer to chart: 4X4 Module (PCM) Diagnostic Trouble Code (DTC) Index (Part 1) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case system, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1825 - P1829, ( P1826 P1827 P1828 1825 1826 1827 1828 1829 ) > System Information > System Diagnosis > P1826 P1825 - P1829: Testing and Inspection P1826 For diagnosis of code P1826, refer to chart: 4X4 Module (PCM) Diagnostic Trouble Code (DTC) Index (Part 2) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case system, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1825 - P1829, ( P1826 P1827 P1828 1825 1826 1827 1828 1829 ) > System Information > System Diagnosis > P1826 > Page 777 P1825 - P1829: Testing and Inspection P1827 For diagnosis of code P1827, refer to chart: 4X4 Module (PCM) Diagnostic Trouble Code (DTC) Index (Part 2) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case system, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1825 - P1829, ( P1826 P1827 P1828 1825 1826 1827 1828 1829 ) > System Information > System Diagnosis > P1826 > Page 778 P1825 - P1829: Testing and Inspection P1828 For diagnosis of code P1828, refer to chart: 4X4 Module (PCM) Diagnostic Trouble Code (DTC) Index (Part 2) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case system, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 P1830 - P1834: Testing and Inspection For diagnosis of code P1830, refer to chart: 4X4 Module (PCM) Diagnostic Trouble Code (DTC) Index (Part 2) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case system, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1845 - P1849, ( P1846 P1847 P1848 1845 1846 1847 1848 1849 ) > System Information > System Diagnosis P1845 - P1849: Testing and Inspection For diagnosis of code P1849, refer to chart: 4X4 Module (PCM) Diagnostic Trouble Code (DTC) Index (Part 2) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case system, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1850 - P1854, ( P1851 P1852 P1853 1850 1851 1852 1853 1854 ) > System Information > System Diagnosis P1850 - P1854: Testing and Inspection For diagnosis of code P1853, refer to chart: 4X4 Module (PCM) Diagnostic Trouble Code (DTC) Index (Part 2) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case system, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1855 - P1859, ( P1856 P1857 P1858 1855 1856 1857 1858 1859 ) > System Information > System Diagnosis P1855 - P1859: Testing and Inspection For diagnosis of code P1857, refer to chart: 4X4 Module (PCM) Diagnostic Trouble Code (DTC) Index (Part 2) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case system, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1860 - P1864, ( P1861 P1862 P1863 1860 1861 1862 1863 1864 ) > System Information > System Diagnosis P1860 - P1864: Testing and Inspection For diagnosis of code P1861, refer to chart: 4X4 Module (PCM) Diagnostic Trouble Code (DTC) Index (Part 2) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case system, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1865 - P1869, ( P1866 P1867 P1868 1865 1866 1867 1868 1869 ) > System Information > System Diagnosis P1865 - P1869: Testing and Inspection For diagnosis of code P1867, refer to chart: 4X4 Module (PCM) Diagnostic Trouble Code (DTC) Index (Part 2) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case system, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1890 - P1894, ( P1891 P1892 P1893 1890 1891 1892 1893 1894 ) > System Information > System Diagnosis P1890 - P1894: Testing and Inspection For diagnosis of code P1891, refer to chart: 4X4 Module (PCM) Diagnostic Trouble Code (DTC) Index (Part 2) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case system, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1900-P19ZZ > P1900 - P1904, ( P1901 P1902 P1903 1900 1901 1902 1903 1904 ) > System Information > System Diagnosis > P1900 P1900 - P1904: Testing and Inspection P1900 For diagnosis of code P1900, refer to chart: P1900 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1900-P19ZZ > P1900 - P1904, ( P1901 P1902 P1903 1900 1901 1902 1903 1904 ) > System Information > System Diagnosis > P1900 > Page 805 P1900 - P1904: Testing and Inspection P1901 For diagnosis of code P1901, refer to chart: P1901 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1900-P19ZZ > P1910 - P1914, ( P1911 P1912 P1913 1910 1911 1912 1913 1914 ) > System Information > System Diagnosis P1910 - P1914: Testing and Inspection For diagnosis of code P1910, refer to chart: P1910 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2000 - P2004, ( P2001 P2002 P2003 2000 2001 2002 2003 2004 ) > System Information > System Diagnosis P2000 - P2004: Testing and Inspection For diagnosis of code P2004, refer to chart: P2004 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2005 - P2009, ( P2006 P2007 P2008 2005 2006 2007 2008 2009 ) > System Information > System Diagnosis > P2005 P2005 - P2009: Testing and Inspection P2005 For diagnosis of code P2005, refer to chart: P2005 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2005 - P2009, ( P2006 P2007 P2008 2005 2006 2007 2008 2009 ) > System Information > System Diagnosis > P2005 > Page 817 P2005 - P2009: Testing and Inspection P2006 For diagnosis of code P2006, refer to chart: P2006 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2005 - P2009, ( P2006 P2007 P2008 2005 2006 2007 2008 2009 ) > System Information > System Diagnosis > P2005 > Page 818 P2005 - P2009: Testing and Inspection P2007 For diagnosis of code P2007, refer to chart: P2007 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2005 - P2009, ( P2006 P2007 P2008 2005 2006 2007 2008 2009 ) > System Information > System Diagnosis > P2005 > Page 819 P2005 - P2009: Testing and Inspection P2008 For diagnosis of code P2008, refer to chart: P2008 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2010 - P2014, ( P2011 P2012 P2013 2010 2011 2012 2013 2014 ) > System Information > System Diagnosis P2010 - P2014: Testing and Inspection For diagnosis of code P2014, refer to chart: P2014 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2015 - P2019, ( P2016 P2017 P2018 2015 2016 2017 2018 2019 ) > System Information > System Diagnosis > P2015 P2015 - P2019: Testing and Inspection P2015 For diagnosis of code P2015, refer to chart: P2015 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2015 - P2019, ( P2016 P2017 P2018 2015 2016 2017 2018 2019 ) > System Information > System Diagnosis > P2015 > Page 827 P2015 - P2019: Testing and Inspection P2019 For diagnosis of code P2019, refer to chart: P2019 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2020 - P2024, ( P2021 P2022 P2023 2020 2021 2022 2023 2024 ) > System Information > System Diagnosis P2020 - P2024: Testing and Inspection For diagnosis of code P2020, refer to chart: P2020 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2065 - P2069, ( P2066 P2067 P2068 2065 2066 2067 2068 2069 ) > System Information > System Diagnosis > P2065 P2065 - P2069: Testing and Inspection P2065 For diagnosis of code P2065, refer to chart: P2065 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2065 - P2069, ( P2066 P2067 P2068 2065 2066 2067 2068 2069 ) > System Information > System Diagnosis > P2065 > Page 835 P2065 - P2069: Testing and Inspection P2066 For diagnosis of code P2066, refer to chart: P2066 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2065 - P2069, ( P2066 P2067 P2068 2065 2066 2067 2068 2069 ) > System Information > System Diagnosis > P2065 > Page 836 P2065 - P2069: Testing and Inspection P2067 For diagnosis of code P2067, refer to chart: P2067 (Part 1) P2067 (Part 2) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2065 - P2069, ( P2066 P2067 P2068 2065 2066 2067 2068 2069 ) > System Information > System Diagnosis > P2065 > Page 837 P2065 - P2069: Testing and Inspection P2068 For diagnosis of code P2068, refer to chart: P2068 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2070 - P2074, ( P2071 P2072 P2073 2070 2071 2072 2073 2074 ) > System Information > System Diagnosis > P2070 P2070 - P2074: Testing and Inspection P2070 For diagnosis of code P2070, refer to chart: P2070 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2070 - P2074, ( P2071 P2072 P2073 2070 2071 2072 2073 2074 ) > System Information > System Diagnosis > P2070 > Page 842 P2070 - P2074: Testing and Inspection P2071 For diagnosis of code P2071, refer to chart: P2071 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2000-P20ZZ > P2070 - P2074, ( P2071 P2072 P2073 2070 2071 2072 2073 2074 ) > System Information > System Diagnosis > P2070 > Page 843 P2070 - P2074: Testing and Inspection P2072 For diagnosis of code P2072, refer to chart: P2072 (Part 1) P2072 (Part 2) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2100 - P2104, ( P2101 P2102 P2103 2100 2101 2102 2103 2104 ) > System Information > System Diagnosis > P2100 P2100 - P2104: Testing and Inspection P2100 For diagnosis of code P2100, refer to chart: P2100 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2100 - P2104, ( P2101 P2102 P2103 2100 2101 2102 2103 2104 ) > System Information > System Diagnosis > P2100 > Page 849 P2100 - P2104: Testing and Inspection P2101 For diagnosis of code P2101, refer to chart: P2101 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2100 - P2104, ( P2101 P2102 P2103 2100 2101 2102 2103 2104 ) > System Information > System Diagnosis > P2100 > Page 850 P2100 - P2104: Testing and Inspection P2104 For diagnosis of code P2104, refer to chart: P2104 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2105 - P2109, ( P2106 P2107 P2108 2105 2106 2107 2108 2109 ) > System Information > System Diagnosis > P2105 P2105 - P2109: Testing and Inspection P2105 For diagnosis of code P2105, refer to chart: P2105 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2105 - P2109, ( P2106 P2107 P2108 2105 2106 2107 2108 2109 ) > System Information > System Diagnosis > P2105 > Page 855 P2105 - P2109: Testing and Inspection P2106 For diagnosis of code P2106, refer to chart: P2106 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2105 - P2109, ( P2106 P2107 P2108 2105 2106 2107 2108 2109 ) > System Information > System Diagnosis > P2105 > Page 856 P2105 - P2109: Testing and Inspection P2107 For diagnosis of code P2107, refer to chart: P2107 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2110 - P2114, ( P2111 P2112 P2113 2110 2111 2112 2113 2114 ) > System Information > System Diagnosis > P2110 P2110 - P2114: Testing and Inspection P2110 For diagnosis of code P2110, refer to chart: P2110 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2110 - P2114, ( P2111 P2112 P2113 2110 2111 2112 2113 2114 ) > System Information > System Diagnosis > P2110 > Page 861 P2110 - P2114: Testing and Inspection P2111 For diagnosis of code P2111, refer to chart: P2111 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2110 - P2114, ( P2111 P2112 P2113 2110 2111 2112 2113 2114 ) > System Information > System Diagnosis > P2110 > Page 862 P2110 - P2114: Testing and Inspection P2112 For diagnosis of code P2112, refer to chart: P2112 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link:See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2120 - P2124, ( P2121 P2122 P2123 2120 2121 2122 2123 2124 ) > System Information > System Diagnosis > P2121 P2120 - P2124: Testing and Inspection P2121 For diagnosis of code P2121, refer to chart: P2121 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2120 - P2124, ( P2121 P2122 P2123 2120 2121 2122 2123 2124 ) > System Information > System Diagnosis > P2121 > Page 867 P2120 - P2124: Testing and Inspection P2122 For diagnosis of code P2122, refer to chart: P2122 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2120 - P2124, ( P2121 P2122 P2123 2120 2121 2122 2123 2124 ) > System Information > System Diagnosis > P2121 > Page 868 P2120 - P2124: Testing and Inspection P2123 For diagnosis of code P2123, refer to chart: P2123 (Part 1) P2123 (Part 2) If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2125 - P2129, ( P2126 P2127 P2128 2125 2126 2127 2128 2129 ) > System Information > System Diagnosis > P2126 P2125 - P2129: Testing and Inspection P2126 For diagnosis of code P2126, refer to chart: P2126 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2125 - P2129, ( P2126 P2127 P2128 2125 2126 2127 2128 2129 ) > System Information > System Diagnosis > P2126 > Page 873 P2125 - P2129: Testing and Inspection P2127 For diagnosis of code P2127, refer to chart: P2127 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2125 - P2129, ( P2126 P2127 P2128 2125 2126 2127 2128 2129 ) > System Information > System Diagnosis > P2126 > Page 874 P2125 - P2129: Testing and Inspection P2128 For diagnosis of code P2128, refer to chart: P2128 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2130 - P2134, ( P2131 P2132 P2133 2130 2131 2132 2133 2134 ) > System Information > System Diagnosis > P2131 P2130 - P2134: Testing and Inspection P2131 For diagnosis of code P2131, refer to chart: P2131 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2130 - P2134, ( P2131 P2132 P2133 2130 2131 2132 2133 2134 ) > System Information > System Diagnosis > P2131 > Page 879 P2130 - P2134: Testing and Inspection P2132 For diagnosis of code P2132, refer to chart: P2132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2130 - P2134, ( P2131 P2132 P2133 2130 2131 2132 2133 2134 ) > System Information > System Diagnosis > P2131 > Page 880 P2130 - P2134: Testing and Inspection P2133 For diagnosis of code P2133, refer to chart: P2133 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2135 - P2139, ( P2136 P2137 P2138 2135 2136 2137 2138 2139 ) > System Information > System Diagnosis P2135 - P2139: Testing and Inspection For diagnosis of code P2135, refer to chart: P2135 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link:See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2195 - P2199, ( P2196 P2197 P2198 2195 2196 2197 2198 2199 ) > System Information > System Diagnosis > P2195 P2195 - P2199: Testing and Inspection P2195 For diagnosis of code P2195, refer to chart: P2195 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2195 - P2199, ( P2196 P2197 P2198 2195 2196 2197 2198 2199 ) > System Information > System Diagnosis > P2195 > Page 888 P2195 - P2199: Testing and Inspection P2196 For diagnosis of code P2196, refer to chart: P2196 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2195 - P2199, ( P2196 P2197 P2198 2195 2196 2197 2198 2199 ) > System Information > System Diagnosis > P2195 > Page 889 P2195 - P2199: Testing and Inspection P2197 For diagnosis of code P2197, refer to chart: P2197 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2195 - P2199, ( P2196 P2197 P2198 2195 2196 2197 2198 2199 ) > System Information > System Diagnosis > P2195 > Page 890 P2195 - P2199: Testing and Inspection P2198 For diagnosis of code P2198, refer to chart: P2198 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2200-P22ZZ > P2255 - P2259, ( P2256 P2257 P2258 2255 2256 2257 2258 2259 ) > System Information > System Diagnosis > P2257 P2255 - P2259: Testing and Inspection P2257 For diagnosis of code P2257, refer to chart: P2257 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2200-P22ZZ > P2255 - P2259, ( P2256 P2257 P2258 2255 2256 2257 2258 2259 ) > System Information > System Diagnosis > P2257 > Page 896 P2255 - P2259: Testing and Inspection P2258 For diagnosis of code P2258, refer to chart: P2258 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2200-P22ZZ > P2270 - P2274, ( P2271 P2272 P2273 2270 2271 2272 2273 2274 ) > System Information > System Diagnosis > P2270 P2270 - P2274: Testing and Inspection P2270 For diagnosis of code P2270, refer to chart: P2270 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2200-P22ZZ > P2270 - P2274, ( P2271 P2272 P2273 2270 2271 2272 2273 2274 ) > System Information > System Diagnosis > P2270 > Page 901 P2270 - P2274: Testing and Inspection P2271 For diagnosis of code P2271, refer to chart: P2271 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2200-P22ZZ > P2270 - P2274, ( P2271 P2272 P2273 2270 2271 2272 2273 2274 ) > System Information > System Diagnosis > P2270 > Page 902 P2270 - P2274: Testing and Inspection P2272 For diagnosis of code P2272, refer to chart: P2272 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2200-P22ZZ > P2270 - P2274, ( P2271 P2272 P2273 2270 2271 2272 2273 2274 ) > System Information > System Diagnosis > P2270 > Page 903 P2270 - P2274: Testing and Inspection P2273 For diagnosis of code P2273, refer to chart: P2273 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2200-P22ZZ > P2270 - P2274, ( P2271 P2272 P2273 2270 2271 2272 2273 2274 ) > System Information > System Diagnosis > P2270 > Page 904 P2270 - P2274: Testing and Inspection P2274 For diagnosis of code P2274, refer to chart: P2274 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2200-P22ZZ > P2275 - P2279, ( P2276 P2277 P2278 2275 2276 2277 2278 2279 ) > System Information > System Diagnosis P2275 - P2279: Testing and Inspection For diagnosis of code P2275, refer to chart: P2275 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2400-P24ZZ > P2445 - P2449, ( P2446 P2447 P2448 2445 2446 2447 2448 2449 ) > System Information > System Diagnosis P2445 - P2449: Testing and Inspection For diagnosis of code P2448, refer to chart: P2448 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2600-P26ZZ > P260F - P260J, ( P260G P260H P260I 260F 260G 260H 260I 260J ) > System Information > System Diagnosis P260F - P260J: Testing and Inspection For diagnosis of code P260F, refer to chart: P260F If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 922 C2075 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 923 Accessory Delay Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 924 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Locations View 151-12 (Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Diagrams > Audio/Navigation Control Unit Navigation Module: Diagrams Audio/Navigation Control Unit C2123a C2123b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Diagrams > Audio/Navigation Control Unit > Page 930 C2123c C2123d Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Diagrams > Audio/Navigation Control Unit > Page 931 C2123e C2123f Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Diagrams > Audio/Navigation Control Unit > Page 932 C2123g C2253a Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Diagrams > Audio/Navigation Control Unit > Page 933 C2253b C2253c Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Diagrams > Audio/Navigation Control Unit > Page 934 C2253d C2253e Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Diagrams > Audio/Navigation Control Unit > Page 935 Navigation Module: Diagrams Navigation Module C2279a C2279b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Diagrams > Page 936 Navigation Module: Service and Repair NAVIGATION MODULE Removal and Installation 1. Disconnect the battery. 2. Remove the lower LH and RH front floor console panels. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Diagrams > Page 937 3. Disconnect the electrical connectors. 4. Remove the navigation module. 1 Remove the 2 navigation module rear screws. 2 Remove the 2 navigation module lateral screws. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-20-5 > Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743 Parking Assist Control Module: Customer Interest Parking Assist System - Speaker Inop./DTC C1742/C1743 TSB 06-20-5 10/16/06 PARKING AID SPEAKER INOPERATIVE - DTCS C1742 AND C1743 FORD: 2005-2007 Five Hundred, Freestyle 2004-2006 Escape, Expedition, Explorer, F-150 2004-2007 F-250, F-350 MERCURY: 2005-2007 Montego 2004-2006 Mountaineer 2005-2006 Mariner ISSUE Some 2004-2007 vehicles equipped with the parking aid reverse sensing system (RSS) may experience low or no audible sound due to speaker issues related to the RSS. The speaker is attached to the module which may exhibit diagnostic trouble codes (DTCs) C1742 (Rear Sounder Circuit Fault) and/or C1743 (Rear Sounder Short). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Verify that DTCs C1742 and/or C1743 are present. Also, low audible or intermittent audible warning condition may exist as well. 2. If DTCs C1742 and/or C1743 are present, replace parking aid speaker on module with speaker in Speaker Kit. Follow instructions in Speaker Kit. 3. Clear DTCs and repeat check for DTCs C1742 and/or C1743. 4. If DTCs C1742 and/or C1743 go away and speaker sounds, the repair is complete. 5. If DTCs remain, follow normal diagnostics in the appropriate Workshop Manual, Section 413-13 Pinpoint Test F. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 062005A 2004-2006 Expedition: 1.2 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2007 Super Duty 0.6 Hr. 250/350: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-20-5 > Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743 > Page 946 062005A 2004-2005 1.1 Hrs. Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2006 Explorer/Mountaineer: 1.3 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 F-150: Replace 0.5 Hr. Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 Escape, 0.8 Hr. 2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Five 1.3 Hrs. Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Freestyle: 0.7 Hr. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR 31012AL, 31012AT) DEALER CODING CONDITION BASIC PART NO. CODE 15K864 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-20-5 > Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743 Parking Assist Control Module: All Technical Service Bulletins Parking Assist System - Speaker Inop./DTC C1742/C1743 TSB 06-20-5 10/16/06 PARKING AID SPEAKER INOPERATIVE - DTCS C1742 AND C1743 FORD: 2005-2007 Five Hundred, Freestyle 2004-2006 Escape, Expedition, Explorer, F-150 2004-2007 F-250, F-350 MERCURY: 2005-2007 Montego 2004-2006 Mountaineer 2005-2006 Mariner ISSUE Some 2004-2007 vehicles equipped with the parking aid reverse sensing system (RSS) may experience low or no audible sound due to speaker issues related to the RSS. The speaker is attached to the module which may exhibit diagnostic trouble codes (DTCs) C1742 (Rear Sounder Circuit Fault) and/or C1743 (Rear Sounder Short). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Verify that DTCs C1742 and/or C1743 are present. Also, low audible or intermittent audible warning condition may exist as well. 2. If DTCs C1742 and/or C1743 are present, replace parking aid speaker on module with speaker in Speaker Kit. Follow instructions in Speaker Kit. 3. Clear DTCs and repeat check for DTCs C1742 and/or C1743. 4. If DTCs C1742 and/or C1743 go away and speaker sounds, the repair is complete. 5. If DTCs remain, follow normal diagnostics in the appropriate Workshop Manual, Section 413-13 Pinpoint Test F. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 062005A 2004-2006 Expedition: 1.2 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2007 Super Duty 0.6 Hr. 250/350: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-20-5 > Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743 > Page 952 062005A 2004-2005 1.1 Hrs. Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2006 Explorer/Mountaineer: 1.3 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 F-150: Replace 0.5 Hr. Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 Escape, 0.8 Hr. 2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Five 1.3 Hrs. Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Freestyle: 0.7 Hr. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR 31012AL, 31012AT) DEALER CODING CONDITION BASIC PART NO. CODE 15K864 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking Assist Control 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking Assist Control Module: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 958 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking Assist Control Module: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 959 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking Assist Control Module: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 965 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Parking Assist Control Module: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 966 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > Page 967 View 151-19 (Left Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > Page 968 Parking Assist Control Module: Diagrams C4014a C4014b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > Page 969 C4226 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > Page 970 Parking Assist Control Module: Service and Repair PARKING AID MODULE Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > Page 971 Removal and Installation 1. Remove the LH quarter trim panel. 2. Remove the parking aid module. 1 Disconnect the electrical connector(s). 2 Remove the parking aid module screw. 3 Remove the parking aid module. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations View 151-26 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 976 Memory Positioning Module: Diagrams C341a C341b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 977 C341c C341d Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Diagrams > Third Row Folding Seat Relay, Left C4183 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Diagrams > Third Row Folding Seat Relay, Left > Page 983 C4184 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left Power Seat Relay: Testing and Inspection Third Row Folding Seat Relay, Left Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 986 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 987 Power Seat Relay: Testing and Inspection Third Row Folding Seat Relay, Right Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 988 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Locations View 151-19 (Left Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Locations > Page 992 Power Trunk / Liftgate Control Module: Diagrams C4174a C4174b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Locations > Page 993 C4174c C4174d Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Locations > Page 994 Power Trunk / Liftgate Control Module: Service and Repair POWER LIFTGATE MODULE Removal and Installation NOTE: Prior to removal of the power liftgate module, it is necessary to upload module configuration information to a diagnostic tool. This information needs to be downloaded into the new power liftgate module once installed. 1. Remove the rear quarter trim panel. 2. Remove the power liftgate module. 1 Disconnect the electrical connectors. 2 Remove the nut. To install, tighten to 11 Nm (8 lb-ft). 3. NOTE: Once the new power liftgate module is installed, it is necessary to download the module configuration information from the diagnostic tool into the new power liftgate module. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D Technical Service Bulletin # 06-13-6 Date: 060710 A/C - Climate Controlled Seats DTC B272C or B272D TSB 06-13-6 07/10/06 DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-14-10 to update the Service Procedure. ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs) B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various sources, making them difficult to diagnose. ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT061306 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14C724 42 Disclaimer Section 1 SECTION 1 1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General Procedures; Supplemental Restraint System Depowering and Repowering. 2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a, C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1003 3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS fails when activated in the heat mode. a. If the time to failure is 5 seconds or less then, proceed to Section 2. b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section 3. c. If the time to failure is 40 seconds or greater, then, proceed to Section 4. NOTE THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4 THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED. THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK. Section 2 SECTION 2 (Seat Shuts Off In Less Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system. a. If there is an over-temp DTC present then go to Step 3. b. If no over-temp DTC is present then go to Step 6. 3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go to Step 4. b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11. c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair as needed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1004 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger cushion) Figure 1.) a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM. b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms? (1) If no, then replace TED. (2) If yes, go to Step 5. 5. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then go to Step 6. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to Step 12. b. If not then proceed to Step 7. 7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then proceed to Step 8. b. If no, then go to Step 9 in Section 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1005 8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) a. If plugged in, then proceed to Step 9. b. If not plugged in, then correct and proceed to Step 12. 9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM). (Figure 2) a. If it is open, then proceed to Step 10. b. If it is not open, then proceed to Step 11. 10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the harnesses). a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step 12. b. If the wire harnesses are good, then proceed to Step 11. 11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms (proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room temperature)? a. No, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. Yes, then replace the DCCSM and proceed to Step 12. 12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to customer. Section 3 SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B). a. If there is an over-temp DTC present, then continue to Step 3. b. If there is no over-temp DTC present, then continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1006 c. If CCS is now operable, then repower the SRS and return vehicle to customer. 3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If readings are hotter than room temperature, go to Step 4. b. If TED temperatures between Back and Cushion are 100 different, go to Step 12. c. If reading correctly then, proceed to Step 5. 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion). (Figure 1) a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on. (1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground. (2) If yes, fix the wiring, if no replace the DCCSM. b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms? (1) If yes, go to Step 5. (2) If no, then replace TED. (Figure 2) 5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, go to Step 6. b. If no, go to Step 7. 6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to Pin 2. a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM, otherwise replace the harness. Verify system now functions and return vehicle to customer. b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system now functions and return vehicle to customer. 7. Cycle ignition and enter into high cool mode. Does failure still occur? a. If no, proceed to Step 8. b. If yes, proceed to Step 13. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1007 8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED connector. NOTE DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE a. If voltage is not getting to the suspect TED, proceed to Step 9. b. If voltage is getting to the suspect TED, replace TED. 9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the module. (Figure 3) ^ Driver Cushion - Pin 9 ^ Driver Backrest - Pin 8 ^ Passenger Cushion - Pin 11 ^ Passenger Backrest - Pin 22 a. If no voltage is coming out of the module, then replace the module and continue to Step 13. b. If the correct voltage is coming out of the module, then continue to Step 10. 10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found, then continue to Step 11. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1008 11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2 volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5) 12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms (proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room temperature)? a. If no, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. If yes, then proceed to Step 13. 13. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1. b. Time to failure is not different than before, then continue to Step 14. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1009 14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7) a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1010 b. If there are no kinks or obstructions of the ducting then, continue to Step 16. 15. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 16. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1011 16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been obstructed or damaged or bunched in the cushion blocking air flow from the TED. a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 17. b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then replace the TED and continue to Step 17. 17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer. Section 4 SECTION 4 (Seat Shuts Off After More Than 40 Seconds) 1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected seat when a heating cycle is initiated. a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2. b. If the TEDs both increase temperature, then proceed to Step 3. 2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED that does not increase temperature from Step 1. a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed to Step 3. b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED, verify the fix and proceed to Step 6. 3. Check for any kinks or obstructions of the ducting from the fan to the TED. a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible otherwise replace the ducting and continue to Step 4. b. If there are no kinks or obstructions of the ducting, then continue to Step 5. 4. If CCS continues to be inoperable with DTC B272C/D code and Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1012 a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 5. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion alignment is incorrect. a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6. b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6. c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 6. d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a climate control seat, then replace the TED and continue to Step 6. 6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer. Section 5 SECTION 5 (Spread Terminal Fix Procedure) 1. Position the front passenger seat fully rearward and up. 2. Pull out and remove the seat track front cover. 3. Disconnect Connector C3265B 24-pin gray. (Figure 3). 4. Remove the red secondary wedge inside the connector. 5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3). NOTE DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG CAVITY. 6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the terminal) and bend the spring into the proper position (Figure 10). 7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the connector. 8. Reconnect C3265B to the dual climate control seat module. 9. Reinstall the seat track front cover. 10. Repower the SRS. Refer to WSM, Section 501-20B. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1013 11. Verify the climate control seat function, and recheck DTCs. 12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D Technical Service Bulletin # 06-13-6 Date: 060710 A/C - Climate Controlled Seats DTC B272C or B272D TSB 06-13-6 07/10/06 DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-14-10 to update the Service Procedure. ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs) B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various sources, making them difficult to diagnose. ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT061306 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14C724 42 Disclaimer Section 1 SECTION 1 1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General Procedures; Supplemental Restraint System Depowering and Repowering. 2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a, C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1019 3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS fails when activated in the heat mode. a. If the time to failure is 5 seconds or less then, proceed to Section 2. b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section 3. c. If the time to failure is 40 seconds or greater, then, proceed to Section 4. NOTE THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4 THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED. THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK. Section 2 SECTION 2 (Seat Shuts Off In Less Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system. a. If there is an over-temp DTC present then go to Step 3. b. If no over-temp DTC is present then go to Step 6. 3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go to Step 4. b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11. c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair as needed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1020 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger cushion) Figure 1.) a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM. b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms? (1) If no, then replace TED. (2) If yes, go to Step 5. 5. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then go to Step 6. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to Step 12. b. If not then proceed to Step 7. 7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then proceed to Step 8. b. If no, then go to Step 9 in Section 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1021 8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) a. If plugged in, then proceed to Step 9. b. If not plugged in, then correct and proceed to Step 12. 9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM). (Figure 2) a. If it is open, then proceed to Step 10. b. If it is not open, then proceed to Step 11. 10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the harnesses). a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step 12. b. If the wire harnesses are good, then proceed to Step 11. 11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms (proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room temperature)? a. No, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. Yes, then replace the DCCSM and proceed to Step 12. 12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to customer. Section 3 SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B). a. If there is an over-temp DTC present, then continue to Step 3. b. If there is no over-temp DTC present, then continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1022 c. If CCS is now operable, then repower the SRS and return vehicle to customer. 3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If readings are hotter than room temperature, go to Step 4. b. If TED temperatures between Back and Cushion are 100 different, go to Step 12. c. If reading correctly then, proceed to Step 5. 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion). (Figure 1) a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on. (1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground. (2) If yes, fix the wiring, if no replace the DCCSM. b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms? (1) If yes, go to Step 5. (2) If no, then replace TED. (Figure 2) 5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, go to Step 6. b. If no, go to Step 7. 6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to Pin 2. a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM, otherwise replace the harness. Verify system now functions and return vehicle to customer. b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system now functions and return vehicle to customer. 7. Cycle ignition and enter into high cool mode. Does failure still occur? a. If no, proceed to Step 8. b. If yes, proceed to Step 13. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1023 8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED connector. NOTE DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE a. If voltage is not getting to the suspect TED, proceed to Step 9. b. If voltage is getting to the suspect TED, replace TED. 9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the module. (Figure 3) ^ Driver Cushion - Pin 9 ^ Driver Backrest - Pin 8 ^ Passenger Cushion - Pin 11 ^ Passenger Backrest - Pin 22 a. If no voltage is coming out of the module, then replace the module and continue to Step 13. b. If the correct voltage is coming out of the module, then continue to Step 10. 10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found, then continue to Step 11. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1024 11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2 volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5) 12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms (proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room temperature)? a. If no, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. If yes, then proceed to Step 13. 13. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1. b. Time to failure is not different than before, then continue to Step 14. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1025 14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7) a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1026 b. If there are no kinks or obstructions of the ducting then, continue to Step 16. 15. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 16. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1027 16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been obstructed or damaged or bunched in the cushion blocking air flow from the TED. a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 17. b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then replace the TED and continue to Step 17. 17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer. Section 4 SECTION 4 (Seat Shuts Off After More Than 40 Seconds) 1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected seat when a heating cycle is initiated. a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2. b. If the TEDs both increase temperature, then proceed to Step 3. 2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED that does not increase temperature from Step 1. a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed to Step 3. b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED, verify the fix and proceed to Step 6. 3. Check for any kinks or obstructions of the ducting from the fan to the TED. a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible otherwise replace the ducting and continue to Step 4. b. If there are no kinks or obstructions of the ducting, then continue to Step 5. 4. If CCS continues to be inoperable with DTC B272C/D code and Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1028 a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 5. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion alignment is incorrect. a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6. b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6. c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 6. d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a climate control seat, then replace the TED and continue to Step 6. 6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer. Section 5 SECTION 5 (Spread Terminal Fix Procedure) 1. Position the front passenger seat fully rearward and up. 2. Pull out and remove the seat track front cover. 3. Disconnect Connector C3265B 24-pin gray. (Figure 3). 4. Remove the red secondary wedge inside the connector. 5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3). NOTE DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG CAVITY. 6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the terminal) and bend the spring into the proper position (Figure 10). 7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the connector. 8. Reconnect C3265B to the dual climate control seat module. 9. Reinstall the seat track front cover. 10. Repower the SRS. Refer to WSM, Section 501-20B. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1029 11. Verify the climate control seat function, and recheck DTCs. 12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 1030 View 151-27 (Passenger Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 1031 Seat Heater Control Module: Diagrams C3265a Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 1032 C3265b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 1033 Seat Heater Control Module: Service and Repair CLIMATE CONTROLLED SEAT MODULE Removal and Installation WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - When installing a new climate control seat module (CCSM), it is necessary to carry out programmable module installation (PMI). 1. Before removing the dual CCSM, carry out the appropriate steps in the PMI procedure. 2. Position the front passenger seat all the way back and up. 3. Depower the SRS. 4. Pull out and remove the seat track front cover. 5. NOTE: The inset shows the dual climate control seat module (CCSM) retaining bracket. Remove the dual CCSM. 1 Pull the back of the dual CCSM away from the seat and slide it off the mounting bracket. 2 Disconnect the electrical connectors. 3 Remove the dual CCSM. 6. To install, reverse the removal procedure. 7. Repower the SRS. 8. Install the CCSM software data. Carry out the appropriate steps in the PMI procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D Technical Service Bulletin # 06-13-6 Date: 060710 A/C - Climate Controlled Seats DTC B272C or B272D TSB 06-13-6 07/10/06 DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-14-10 to update the Service Procedure. ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs) B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various sources, making them difficult to diagnose. ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT061306 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14C724 42 Disclaimer Section 1 SECTION 1 1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General Procedures; Supplemental Restraint System Depowering and Repowering. 2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a, C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1042 3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS fails when activated in the heat mode. a. If the time to failure is 5 seconds or less then, proceed to Section 2. b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section 3. c. If the time to failure is 40 seconds or greater, then, proceed to Section 4. NOTE THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4 THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED. THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK. Section 2 SECTION 2 (Seat Shuts Off In Less Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system. a. If there is an over-temp DTC present then go to Step 3. b. If no over-temp DTC is present then go to Step 6. 3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go to Step 4. b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11. c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair as needed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1043 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger cushion) Figure 1.) a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM. b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms? (1) If no, then replace TED. (2) If yes, go to Step 5. 5. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then go to Step 6. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to Step 12. b. If not then proceed to Step 7. 7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then proceed to Step 8. b. If no, then go to Step 9 in Section 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1044 8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) a. If plugged in, then proceed to Step 9. b. If not plugged in, then correct and proceed to Step 12. 9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM). (Figure 2) a. If it is open, then proceed to Step 10. b. If it is not open, then proceed to Step 11. 10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the harnesses). a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step 12. b. If the wire harnesses are good, then proceed to Step 11. 11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms (proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room temperature)? a. No, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. Yes, then replace the DCCSM and proceed to Step 12. 12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to customer. Section 3 SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B). a. If there is an over-temp DTC present, then continue to Step 3. b. If there is no over-temp DTC present, then continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1045 c. If CCS is now operable, then repower the SRS and return vehicle to customer. 3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If readings are hotter than room temperature, go to Step 4. b. If TED temperatures between Back and Cushion are 100 different, go to Step 12. c. If reading correctly then, proceed to Step 5. 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion). (Figure 1) a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on. (1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground. (2) If yes, fix the wiring, if no replace the DCCSM. b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms? (1) If yes, go to Step 5. (2) If no, then replace TED. (Figure 2) 5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, go to Step 6. b. If no, go to Step 7. 6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to Pin 2. a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM, otherwise replace the harness. Verify system now functions and return vehicle to customer. b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system now functions and return vehicle to customer. 7. Cycle ignition and enter into high cool mode. Does failure still occur? a. If no, proceed to Step 8. b. If yes, proceed to Step 13. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1046 8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED connector. NOTE DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE a. If voltage is not getting to the suspect TED, proceed to Step 9. b. If voltage is getting to the suspect TED, replace TED. 9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the module. (Figure 3) ^ Driver Cushion - Pin 9 ^ Driver Backrest - Pin 8 ^ Passenger Cushion - Pin 11 ^ Passenger Backrest - Pin 22 a. If no voltage is coming out of the module, then replace the module and continue to Step 13. b. If the correct voltage is coming out of the module, then continue to Step 10. 10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found, then continue to Step 11. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1047 11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2 volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5) 12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms (proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room temperature)? a. If no, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. If yes, then proceed to Step 13. 13. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1. b. Time to failure is not different than before, then continue to Step 14. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1048 14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7) a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1049 b. If there are no kinks or obstructions of the ducting then, continue to Step 16. 15. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 16. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1050 16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been obstructed or damaged or bunched in the cushion blocking air flow from the TED. a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 17. b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then replace the TED and continue to Step 17. 17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer. Section 4 SECTION 4 (Seat Shuts Off After More Than 40 Seconds) 1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected seat when a heating cycle is initiated. a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2. b. If the TEDs both increase temperature, then proceed to Step 3. 2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED that does not increase temperature from Step 1. a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed to Step 3. b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED, verify the fix and proceed to Step 6. 3. Check for any kinks or obstructions of the ducting from the fan to the TED. a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible otherwise replace the ducting and continue to Step 4. b. If there are no kinks or obstructions of the ducting, then continue to Step 5. 4. If CCS continues to be inoperable with DTC B272C/D code and Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1051 a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 5. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion alignment is incorrect. a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6. b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6. c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 6. d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a climate control seat, then replace the TED and continue to Step 6. 6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer. Section 5 SECTION 5 (Spread Terminal Fix Procedure) 1. Position the front passenger seat fully rearward and up. 2. Pull out and remove the seat track front cover. 3. Disconnect Connector C3265B 24-pin gray. (Figure 3). 4. Remove the red secondary wedge inside the connector. 5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3). NOTE DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG CAVITY. 6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the terminal) and bend the spring into the proper position (Figure 10). 7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the connector. 8. Reconnect C3265B to the dual climate control seat module. 9. Reinstall the seat track front cover. 10. Repower the SRS. Refer to WSM, Section 501-20B. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1052 11. Verify the climate control seat function, and recheck DTCs. 12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 06-5-1 > Mar > 06 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D Technical Service Bulletin # 06-13-6 Date: 060710 A/C - Climate Controlled Seats DTC B272C or B272D TSB 06-13-6 07/10/06 DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-14-10 to update the Service Procedure. ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs) B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various sources, making them difficult to diagnose. ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT061306 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14C724 42 Disclaimer Section 1 SECTION 1 1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General Procedures; Supplemental Restraint System Depowering and Repowering. 2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a, C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 06-5-1 > Mar > 06 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1062 3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS fails when activated in the heat mode. a. If the time to failure is 5 seconds or less then, proceed to Section 2. b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section 3. c. If the time to failure is 40 seconds or greater, then, proceed to Section 4. NOTE THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4 THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED. THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK. Section 2 SECTION 2 (Seat Shuts Off In Less Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system. a. If there is an over-temp DTC present then go to Step 3. b. If no over-temp DTC is present then go to Step 6. 3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go to Step 4. b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11. c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair as needed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 06-5-1 > Mar > 06 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1063 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger cushion) Figure 1.) a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM. b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms? (1) If no, then replace TED. (2) If yes, go to Step 5. 5. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then go to Step 6. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to Step 12. b. If not then proceed to Step 7. 7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then proceed to Step 8. b. If no, then go to Step 9 in Section 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 06-5-1 > Mar > 06 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1064 8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) a. If plugged in, then proceed to Step 9. b. If not plugged in, then correct and proceed to Step 12. 9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM). (Figure 2) a. If it is open, then proceed to Step 10. b. If it is not open, then proceed to Step 11. 10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the harnesses). a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step 12. b. If the wire harnesses are good, then proceed to Step 11. 11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms (proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room temperature)? a. No, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. Yes, then replace the DCCSM and proceed to Step 12. 12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to customer. Section 3 SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B). a. If there is an over-temp DTC present, then continue to Step 3. b. If there is no over-temp DTC present, then continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 06-5-1 > Mar > 06 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1065 c. If CCS is now operable, then repower the SRS and return vehicle to customer. 3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If readings are hotter than room temperature, go to Step 4. b. If TED temperatures between Back and Cushion are 100 different, go to Step 12. c. If reading correctly then, proceed to Step 5. 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion). (Figure 1) a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on. (1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground. (2) If yes, fix the wiring, if no replace the DCCSM. b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms? (1) If yes, go to Step 5. (2) If no, then replace TED. (Figure 2) 5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, go to Step 6. b. If no, go to Step 7. 6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to Pin 2. a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM, otherwise replace the harness. Verify system now functions and return vehicle to customer. b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system now functions and return vehicle to customer. 7. Cycle ignition and enter into high cool mode. Does failure still occur? a. If no, proceed to Step 8. b. If yes, proceed to Step 13. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 06-5-1 > Mar > 06 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1066 8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED connector. NOTE DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE a. If voltage is not getting to the suspect TED, proceed to Step 9. b. If voltage is getting to the suspect TED, replace TED. 9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the module. (Figure 3) ^ Driver Cushion - Pin 9 ^ Driver Backrest - Pin 8 ^ Passenger Cushion - Pin 11 ^ Passenger Backrest - Pin 22 a. If no voltage is coming out of the module, then replace the module and continue to Step 13. b. If the correct voltage is coming out of the module, then continue to Step 10. 10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found, then continue to Step 11. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 06-5-1 > Mar > 06 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1067 11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2 volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5) 12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms (proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room temperature)? a. If no, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. If yes, then proceed to Step 13. 13. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1. b. Time to failure is not different than before, then continue to Step 14. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 06-5-1 > Mar > 06 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1068 14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7) a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 06-5-1 > Mar > 06 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1069 b. If there are no kinks or obstructions of the ducting then, continue to Step 16. 15. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 16. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 06-5-1 > Mar > 06 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1070 16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been obstructed or damaged or bunched in the cushion blocking air flow from the TED. a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 17. b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then replace the TED and continue to Step 17. 17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer. Section 4 SECTION 4 (Seat Shuts Off After More Than 40 Seconds) 1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected seat when a heating cycle is initiated. a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2. b. If the TEDs both increase temperature, then proceed to Step 3. 2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED that does not increase temperature from Step 1. a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed to Step 3. b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED, verify the fix and proceed to Step 6. 3. Check for any kinks or obstructions of the ducting from the fan to the TED. a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible otherwise replace the ducting and continue to Step 4. b. If there are no kinks or obstructions of the ducting, then continue to Step 5. 4. If CCS continues to be inoperable with DTC B272C/D code and Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 06-5-1 > Mar > 06 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1071 a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 5. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion alignment is incorrect. a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6. b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6. c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 6. d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a climate control seat, then replace the TED and continue to Step 6. 6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer. Section 5 SECTION 5 (Spread Terminal Fix Procedure) 1. Position the front passenger seat fully rearward and up. 2. Pull out and remove the seat track front cover. 3. Disconnect Connector C3265B 24-pin gray. (Figure 3). 4. Remove the red secondary wedge inside the connector. 5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3). NOTE DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG CAVITY. 6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the terminal) and bend the spring into the proper position (Figure 10). 7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the connector. 8. Reconnect C3265B to the dual climate control seat module. 9. Reinstall the seat track front cover. 10. Repower the SRS. Refer to WSM, Section 501-20B. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 06-5-1 > Mar > 06 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1072 11. Verify the climate control seat function, and recheck DTCs. 12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > Page 1073 P1275 - P1279: Testing and Inspection P1276 For diagnosis of code P1276, refer to chart: P1276 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations View 151-23 (Roof) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 1077 C921 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations > Page 1081 C2110 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations > Page 1082 Trailer Towing Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations > Page 1083 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 1088 C135 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 1089 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System (ABS) Module Removal and Installation NOTE: When installing a new module, it must be calibrated and configured (either by download/upload or uploading the as-built data method). 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the anti-lock brake system (ABS) module electrical connector. 3. Remove the 3 bolts and the ABS module. ^ To install, tighten to 2 Nm (18 inch lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 1090 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay Blower Motor Relay: Locations Front Blower Motor Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay > Page 1096 View 151-1 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay > Page 1097 Blower Motor Relay: Locations Rear Blower Motor Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay > Page 1098 View 151-21 (Right Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Front Blower Motor Relay C2216 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Front Blower Motor Relay > Page 1101 C4075 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay Blower Motor Relay: Testing and Inspection Front Blower Motor Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 1104 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 1105 Blower Motor Relay: Testing and Inspection Rear Blower Motor Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 1106 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 1110 View 151-1 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 1111 C1008 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 1112 Compressor Clutch Relay: Description and Operation AIR CONDITIONING (A/C) CLUTCH RELAY (A/CCR) NOTE: The PCM PIDs WAC and wide open throttle air conditioning cutoff fault (WACF) are used to monitor the A/CCR output. The A/CCR (may be referred to as the wide open throttle A/C cutoff [WAC] relay) is wired normally open. There is no direct electrical connection between the A/C switch or EATC module and the A/C clutch. The PCM receives a signal indicating that A/C is requested (for some applications, this message is sent through the communications network). When A/C is requested, the PCM will check other A/C related inputs that are available (such as ACPSW, ACCS). If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant temperature, engine RPM, throttle position), the PCM grounds the A/CCR output, closing the relay contacts and sending voltage to the A/CC. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 1113 Compressor Clutch Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 1114 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations View 151-12 (Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Page 1118 Control Module HVAC: Diagrams C228a Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Page 1119 C228b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 1124 C1474 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 1125 Backup Lamp Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 1126 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations Battery Discharge Protection Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 1130 View 151-1 (Engine Compartment) The battery savar relay is part of the central junction box (CJB) and is Not Serviceable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations Courtesy Lamp Relay: Locations View 151-12 (Dash Panel) The interior lamp relay is located in the instrument cluster and is Not Serviceable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Daytime Running Lamps (DRL) Headlamp Relay Daytime Running Lamp Relay: Locations Daytime Running Lamps (DRL) Headlamp Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Daytime Running Lamps (DRL) Headlamp Relay > Page 1138 View 151-1 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Daytime Running Lamps (DRL) Headlamp Relay > Page 1139 Daytime Running Lamp Relay: Locations Daytime Running Lamps (DRL) Ignition Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Daytime Running Lamps (DRL) Headlamp Relay > Page 1140 View 151-1 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Daytime Running Lamps (DRL) Headlamp Relay C1359 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Daytime Running Lamps (DRL) Headlamp Relay > Page 1143 C1171 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Daytime Running Lamps (DRL) Headlamp Relay Daytime Running Lamp Relay: Testing and Inspection Daytime Running Lamps (DRL) Headlamp Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Daytime Running Lamps (DRL) Headlamp Relay > Page 1146 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Daytime Running Lamps (DRL) Headlamp Relay > Page 1147 Daytime Running Lamp Relay: Testing and Inspection Daytime Running Lamps (DRL) Ignition Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Daytime Running Lamps (DRL) Headlamp Relay > Page 1148 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 1152 C2241 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 1153 Fog/Driving Lamp Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 1154 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Page 1158 C2047 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Page 1159 Hazard Flasher Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Page 1160 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations > Page 1164 C2242 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations > Page 1165 High Beam Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations > Page 1166 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 1170 View 151-1 (Engine Compartment) The horn relay is part of the central junction box (CJB) and is Not Serviceable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations Interior Lighting Relay: Locations View 151-12 (Dash Panel) The interior lamp relay is located in the instrument cluster and is Not Serviceable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Electronic Park Brake Release Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Electronic Park Brake Release Relay > Page 1178 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Electronic Park Brake Release Relay C2244 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Electronic Park Brake Release Relay > Page 1181 C2245 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Testing and Inspection > Electronic Park Brake Release Relay Parking Lamp Relay: Testing and Inspection Electronic Park Brake Release Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Testing and Inspection > Electronic Park Brake Release Relay > Page 1184 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Testing and Inspection > Electronic Park Brake Release Relay > Page 1185 Parking Lamp Relay: Testing and Inspection Electronic Park Brake Reset Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Testing and Inspection > Electronic Park Brake Release Relay > Page 1186 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 1191 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Trailer Tow Relay, Parking Lamp C2240 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Trailer Tow Relay, Parking Lamp > Page 1194 C2110 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 1197 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 1198 Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Battery Charge Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 1199 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations > Page 1203 C2047 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations > Page 1204 Turn Signal Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations > Page 1205 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 1210 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 1214 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 1218 C2110 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 1219 Power Distribution Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 1220 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box Relay Box: Locations Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 1225 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 1226 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 1227 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 1228 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 1229 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 1230 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 1231 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 1232 Relay Box: Locations Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 1233 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 1234 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 1235 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 1236 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 1237 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 1238 Relay Box: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 1239 C270a Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 1240 C270b C270c Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 1241 C270d Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 1242 C270e Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 1243 C270f C270g Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 1244 C270h C270j Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 1245 C270k C270m Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 1246 C270n C270p Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box Relay Box: Application and ID Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 1249 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 1250 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 1251 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 1252 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 1253 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 1254 Relay Box: Application and ID Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 1255 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 1256 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 1257 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 1258 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 1259 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 1260 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 1261 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations Body Control Module: Locations VEHICLE SECURITY MODULE (VSM) View 151-17 (RH A-Pillar) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Page 1267 Body Control Module: Diagrams VEHICLE SECURITY MODULE (VSM) C2113a C2113b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Page 1268 C2113c Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) Body Control Module: Service and Repair Driver Seat Module (DSM) DRIVER SEAT MODULE (DSM) Removal and Installation CAUTION: - Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. - Prior to the removal of the module, it is necessary to upload module configuration information to the appropriate diagnostic equipment. This information needs to be downloaded into the new module once installed. 1. NOTE: The module is accessed with the seat fully in the UP position. Position the driver seat module forward to remove it from the bracket. 2. Disconnect the battery. 3. Disconnect the electrical connectors and remove the DSM. 4. CAUTION: Once the module is installed it is necessary to download the module configuration information from the diagnostic tool into the new module. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 1271 Body Control Module: Service and Repair Vehicle Security Module VEHICLE SECURITY MODULE Removal CAUTION: The steps included in the vehicle security module removal and installation procedure are critical to restoring the vehicle security and tire pressure monitoring systems to normal operation. A new vehicle security module is delivered in manufacturing mode with 6 pre-set diagnostic trouble codes (DTCs) related to the tire pressure monitoring system (TPMS). The presence of these DTCs requires the installation procedures be followed in order to clear the DTCs and enable normal vehicle security module operations. 1. NOTE: Prior to the removal of the vehicle security module, it is necessary to upload the module configuration information to the diagnostic tool. This information must be downloaded to the new vehicle security module after installation. Disconnect the battery. 2. Remove the pin-type retainer and the RH A-pillar lower trim panel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 1272 3. Remove the glove compartment. 4. Disconnect the 3 electrical connectors. 5. Remove the 2 screws and the vehicle security module. Installation 1. Position the vehicle security module and install the 2 screws. - Tighten the screws to 6 Nm (53 lb-in). 2. Connect the 3 electrical connectors. 3. Position the RH A-pillar lower trim panel and install the pin-type retainer. 4. Install the glove compartment 5. Connect the battery. 6. NOTE: When successful, this step provides the calibration necessary for vehicle security module operation and clears DTC B2477. The clearing of the DTC indicates the calibration data has been successfully downloaded to the vehicle security module. Download the vehicle security module configuration information from the diagnostic tool to the vehicle security module. 7. NOTE: When successful, this step clears DTCs B2868, B2869, B2870 and B2871. The clearing of these DTCs indicates the vehicle security module has recognized the tire pressure sensors during the training procedure. Train the tire pressure sensors. 8. Clear the DTCs. 9. NOTE: - DTC C2780 will not clear if any other DTCs are present in the vehicle security module. - This step is required to clear DTC C2780, allow the vehicle security module to exit the manufacturing mode, and to be sure there are no other concerns with the newly programmed vehicle security module. Carry out the vehicle security module on-demand self-test. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation Electronic Throttle Control Module: Description and Operation TORQUE BASED ELECTRONIC THROTTLE CONTROL (ETC) Overview The torque based ETC is a hardware and software strategy that delivers an engine output torque (via throttle angle) based on driver demand (pedal position). It uses an electronic throttle body, the powertrain control module (PCM), and an accelerator pedal assembly to control the throttle opening and engine torque. The ETC system replaces the standard cable operated accelerator pedal, idle air control (IAC) valve, 3-wire throttle position sensor (TPS), and mechanical throttle body. Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque during shifts, and by calculating this desired torque, the system prevents engine lugging (low RPM and low manifold vacuum) while still delivering the performance and torque requested by the driver. It also enables many fuel economy/emission improvement technologies such as variable camshaft timing (VCT) (deliver same torque during transitions). Torque based ETC also results in less intrusive vehicle and engine speed limiting, along with smoother traction control. Other benefits of ETC are: eliminate cruise control actuators - eliminate idle air control (IAC) valve - better airflow range - packaging (no cable) - more responsive powertrain at altitude and improved shift quality It should be noted that the ETC system illuminates a powertrain malfunction indicator (wrench) on the instrument cluster when a concern is present. Concerns are accompanied by diagnostic trouble codes (DTCs) and may also illuminate the malfunction indicator lamp (MIL). Electronic Throttle Body (ETB) The ETB has the following characteristics: 1. The throttle actuator control (TAC) motor is a DC motor controlled by the PCM (requires 2-wires). The gear ratio from the motor to the throttle plate shaft is 17:1. 2. There are 2 designs: parallel and in-series. The parallel design has the motor under the bore parallel to the plate shaft. The motor housing is integrated into the main housing. The in-series design has a separate motor housing. 3. Two springs are used: one is used to close the throttle (main spring) and the other is in a plunger assembly that results in a default angle when no power is applied. This is for limp home reasons (the force of the plunger spring is 2 times stronger than the main spring). The default angle is usually set to result in a top vehicle speed of 48 km/h (30 mph) Typically this throttle angle is 7 to 8 degrees from the hard-stop angle. 4. The closed throttle plate hard stop is used to prevent the throttle from binding in the bore (~0.75 degree). This hard stop setting is not adjustable and is set to result in less airflow than the minimum engine airflow required at idle. 5. Unlike cable operated throttle bodies, the intent for the ETB is not to have a hole in the throttle plate or to use plate sealant. The hole is not required in the ETB because the required idle airflow is provided by the plate angle in the throttle body assembly. This plate angle controls idle, idle quality, and eliminates the need for an IAC valve. 6. The throttle position (TP) sensor has 2 signal circuits in the sensor for redundancy. The redundant throttle position signals are required for increased monitoring reasons. The first TP signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). During normal operation the negative slope TP signal (TP1) is used by the control strategy as the indication of throttle position. The TP sensor assembly requires 4 circuits. 5-volt reference voltage - Signal return (ground) - TP1 voltage with negative voltage slope (5-0 volts) - TP2 voltage with positive voltage slope (0-5 volts) Accelerator Pedal Position (APP) Sensors Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 1276 Electronic Throttle Body (ETB) And Accelerator Pedal Assembly The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1. There are 3 pedal position signals required for system monitoring. APP1 has a negative slope (increasing angle, decreasing voltage) and APP2 and APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. 2. There are 2 VREF circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. 2 reference voltage circuits (5 volts) - 2 signal return (ground) circuits - APP1 voltage with negative voltage slope (5-0 volts) - APP2 voltage with positive voltage slope (0-5 volts) - APP3 voltage with positive voltage slope (0-5 volts) 3. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. 4. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. A value is substituted for an incorrect signal if 2 of the 3 signals are incorrect. Electronic Throttle Control (ETC) System Strategy Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 1277 ETC System The torque based ETC strategy was developed to improve fuel economy and to accommodate variable camshaft timing (VCT). This is possible by not coupling the throttle angle to the driver pedal position. Uncoupling the throttle angle (produce engine torque) from the pedal position (driver demand) allows the powertrain control strategy to optimize fuel control and transmission shift schedules while delivering the requested wheel torque. The ETC monitor system is distributed across 2 processors within the PCM: the main powertrain control processor unit (CPU) and a monitoring processor called an enhanced-quizzer (E-Quizzer) processor. The primary monitoring function is carried out by the independent plausibility check (IPC) software, which resides on the main processor. It is responsible for determining the driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the generated torque exceeds driver demand by a specified amount, the IPC takes appropriate corrective action. ETC System Failure Mode And Effects Management (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 1278 ETC System Failure Mode And Effects Management (Part 2) Since the IPC and the main controller share the same processor, they are subject to a number of potential common failure modes. Therefore, the E-Quizzer processor was added to redundantly monitor selected PCM inputs and to act as an intelligent watchdog and monitor the performance of the IPC and the main processor. If it determines that the IPC function is impaired in any way, it takes appropriate failure mode and effects management (FMEM) actions. Electronic Throttle Monitor Operation: Electronic Throttle Monitor Operation (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 1279 Electronic Throttle Monitor Operation (Part 2) Accelerator and Throttle Position (TP) Sensor Inputs Accelerator Pedal Position (APP) Sensor Check: Accelerator Pedal Position (APP) Sensor Check Throttle Position (TP) Sensor Check: Throttle Position (TP) Sensor Check Throttle Plate Position Controller (TPPC) Outputs Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 1280 Throttle Plate Controller Check Operation The purpose of the TPPC is to maintain the throttle position at the desired throttle angle. It is a separate chip embedded in the PCM. The desired angle is communicated from the main CPU via a 312.5 Hz duty cycle (DC) signal. The TPPC interprets the duty cycle signal as follows: Less than 5% - Out of range, limp home default position. - Greater than or equal to 5% but less than 6% - Commanded default position, closed. - Greater than or equal to 6% but less than 7% - Commanded default position. Used for key-on, engine off. - Greater than or equal to 7% but less than 10% - Closed against hard-stop. Used to learn zero throttle angle position (hard-stop) after key-up. - Greater than or equal to 10% but less than or equal to 92% - Normal operation, between 0 degrees (hard-stop) and 82 degrees, 10% duty cycle equals 0 degrees throttle angle, 92% duty cycle equals 82 degrees throttle angle. - Greater than 92% but less than or equal to 96% - Wide Open Throttle, 82 to 86 degrees throttle angle. - Greater than 96% but less than or equal to 100% - Out of Range, limp home default position. The desired angle is relative to the hard-stop angle. The hard-stop angle is learned during each key-up process before the main CPU requests the throttle plate be closed against the hard-stop. The output of the TPPC is a voltage request to the H-driver (also in PCM). The H driver is capable of positive or negative voltage to the electronic throttle body motor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations View 151-1 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 1286 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 1287 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 1288 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 1289 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 1290 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 1291 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 1292 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 1293 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 1294 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 1295 Engine Control Module: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 1296 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 1297 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 1298 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 1299 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 1300 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 1301 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 1302 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 1303 Engine Control Module: Connector Views C175b (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 1304 C175b (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 1305 C175e (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 1306 C175e (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 1307 C175t (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 1308 C175t (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 > Flash Electrically Erasable Programmable Read Only Memory (EEPROM) Engine Control Module: Service and Repair Flash Electrically Erasable Programmable Read Only Memory (EEPROM) FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) Description The flash electrically erasable programmable read only memory (EEPROM) is contained in an integrated circuit (IC) internal to the powertrain control module (PCM). The EEPROM contains the vehicle strategy including calibration information specific to the vehicle, and is capable of being programmed or flashed repeatedly. As part of the calibration there is an area referred to as the vehicle identification (VID) block. The VID block is programmed when installing a new PCM as described under Programming the VID Block for a Replacement PCM. Failure to carry out this procedure may generate fault code P1635 or P1639. The VID block in an existing PCM can also be tailored to accommodate various hardware or parameter changes made to the vehicle since production. Failure to carry out this procedure properly may generate fault code P1635, Tire/Axle Ratio out of Acceptable Range. An incorrect tire/axle ratio is one of the main causes for fault code P1639. This is described under Making Changes to the VID Block and also under Making Changes to the PCM Calibration. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the vehicle identification number (VIN), octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control, and 4-wheel drive electronic shift-on-the-fly (ESOF) versus manual shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported by the VID block is displayed on the diagnostic tool. When changing items in the VID block, the strategy places range limits on certain items such as tire and axle ratio. The number of times the VID block may be reconfigured is limited. When this limit is reached, the diagnostic tool displays a message indicating the need to flash the PCM again to reset the VID block. Programming can be carried out by a local Ford dealer or any non-Ford facility. Refer to the diagnostic tool manufacturer's instruction manual for details. Programming the VID Block for a Replacement PCM A new PCM contains the latest strategy and calibration level for a particular vehicle. However, the VID block is blank and will need programming. There are 2 procedures available. The first is an automatic data transfer from the old PCM to the new PCM, and the second is manual data entry into the new PCM. Automatic data transfer is carried out if the old PCM is capable of communicating. This is done by the use of a diagnostic tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can then be downloaded to the new PCM after it has been installed. Manual data entry must be carried out if the old module is damaged or incapable of communicating. Remove and install a new PCM. Using a compatible diagnostic tool, select and carry out the module/parameter programming, referring to the diagnostic tool manufacturer's instruction manual. Make certain that all parameters are included. Failure to properly program tire size in revolutions per mile, (rev/mile equals 63,360 divided by the tire circumference in inches), axle ratio, 4x4/4x2, and/or MSOF/ESOF may result in codes P1635 and P1639. You may be instructed to contact the As-Built Data Center for the information needed to manually update the VID block with the diagnostic tool. Contact the center only if the old PCM cannot be used or the data is corrupt. For Ford and L-M technicians, contact your National Hotline or the Professional Technician Society (PTS) website for As-Built data listed under the Service Publications Index. Non-Ford technicians use the Motorcraft(R) website at www.motorcraft.com. From the Motorcraft(R) homepage, use the search function to find the Module Programming or As-Built Data. For Ford and L-M technicians, check the Programmable Module Installation link on the PTS website for quick Programmable Module data information by vehicle when using the worldwide diagnostic system (WDS) or New Generation STAR (NGS). Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate the vehicle hardware. Refer to PCM/Module Reprogramming on the diagnostic tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM needs to be completely reprogrammed. This is due to changes made to the strategy or calibration after production, or the need to reset the VID block because it has reached its limit. Refer to PCM/Module Reprogramming on the diagnostic tool. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 > Flash Electrically Erasable Programmable Read Only Memory (EEPROM) > Page 1311 Engine Control Module: Service and Repair Removal and Installation POWERTRAIN CONTROL MODULE (PCM) Special Tool(s) Special Tool(s) Removal and Installation 1. NOTE: Refer to Computers and Control Systems for correct worldwide diagnostic system (WDS) hook-up procedure. If servicing the powertrain control module (PCM), connect the diagnostic tool to the vehicle. Allow the diagnostic tool to identify the vehicle and obtain configuration data. All programmable module information will automatically be retrieved by the WDS. 2. Disconnect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 > Flash Electrically Erasable Programmable Read Only Memory (EEPROM) > Page 1312 3. Disconnect the PCM electrical connectors. 4. Remove the 4 bolts and the PCM. - To install, tighten to 7 Nm (62 lb-in). 5. If servicing the PCM bracket, remove the 3 bolts and the PCM bracket. - To install, tighten to 10 Nm (89 lb-in). 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 1316 C2160 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 1317 Main Relay (Computer/Fuel System): Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 1318 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations View 151-36 (Chassis, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 1323 C4033 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 1324 Fuel Pump Control Unit: Service and Repair Fuel Pump Driver Module (FPDM) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. NOTE: The fuel pump driver module (FPDM) is located on the top of the LH frame rail near the fuel tank filler pipe. Disconnect the FPDM electrical connector. 4. Remove the bolts and the FPDM. - To install, tighten to 10 Nm (89 lb-in). 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 (V8-5.4L VIN 5 (2006)) 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 1328 View 151-1 (Engine Compartment) The fuel pump relay is located in the Central Junction Box (CJB) and is Not Serviceable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 1332 C2160 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 1333 Main Relay (Computer/Fuel System): Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 1334 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations View 151-15 (LH A-Pillar) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 1339 Air Bag And Safety Belt Pretensioner Supplemental Restraint System (SRS) Deployable Components (Part 1) Air Bag And Safety Belt Pretensioner Supplemental Restraint System (SRS) Deployable Components (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 1340 Air Bag And Safety Belt Pretensioner Supplemental Restraint System (SRS) Sensor Components (Part 1) Air Bag And Safety Belt Pretensioner Supplemental Restraint System (SRS) Sensor Components (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 1341 Air Bag Control Module: Diagrams C310a Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 1342 C310b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 1343 Air Bag Control Module: Description and Operation RESTRAINTS CONTROL MODULE (RCM) WARNING: - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the RCM must be replaced whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. NOTE: When installing a new restraints control module (RCM), always make sure the correct RCM is being installed. If an incorrect RCM is installed, erroneous DTCs will result. The restraints control module (RCM) carries out the following functions: - deploys the air bag(s) in the event of a deployable crash. - activates the safety belt buckle pretensioners to remove slack from the safety belt. - monitors the 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 instrument cluster module to activate a chime if the air bag indicator is not available and another SRS fault exists. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the ON position, the RCM will 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 prove out by lighting for 6 seconds and then off for 2 seconds. After the prove out, the air bag indicator will then flash the 2-digit LFC. If an SRS fault exists, the air bag indicator will flash the LFC 5 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 DLC, to the diagnostic tool. If the air bag indicator does not function, and the system detects a fault condition, the RCM will signal the instrument cluster module to activate an audible chime. The chime is a series of 5 sets of 5 tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If 2 or more faults occur at the same time, the fault having the highest priority will be displayed. After that 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 front air bags and safety belt pretensioners in the event that the ignition circuit is lost or damaged during impact. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 1344 Air Bag Control Module: Service and Repair RESTRAINTS CONTROL MODULE (RCM) Vehicles With A Center Console Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 1345 Vehicles With 60/40 Front Bench Seat 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. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - The restraints control module (RCM) orientation is critical for proper air bag supplemental restraint system (SRS) operation. If a vehicle equipped with an SRS system has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the RCM must be replaced whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. - To reduce the risk of personal injury, do not use any memory saver devices. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - When installing a new restraints control module (RCM), always make sure the correct RCM is being installed. If an incorrect RCM is installed, erroneous DTCs will result. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. All vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 1346 1. Depower the system. Vehicles with a center console 2. Remove the center console. Vehicles with 60/40 front bench seat 3. Remove the 60 percent portion of the front bench seat. 4. Remove the 3 nuts and the restraints control module (RCM) top bracket. 5. WARNING: Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. Remove the 3 nuts and separate the RCM from the bracket. All vehicles 6. Disconnect the small restraints control module (RCM) electrical connector. 1 Push down to release the retaining tab. 2 While releasing the retaining tab, pull out and disconnect the small RCM electrical connector. 7. Disconnect the large RCM electrical connector. 1 Pinch the thumb tab and pivot the connector position assurance lever away from the RCM, disengaging the lever. 2 Pull out and disconnect the large RCM electrical connector. Vehicles with 60/40 front bench seat 8. Remove the RCM. Vehicles with a center console 9. Remove the 4 RCM bracket bolts and RCM with the bracket. Installation Vehicles with a center console 1. WARNING: The tightening torque of the air bag restraints control module (RCM) bracket retaining bolts is critical for correct system operation. Position the RCM with bracket and install the 4 bolts. Tighten to 12 Nm (9 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 1347 All vehicles 2. Make sure the connector position assurance lever is in the full release position before attempting to connect the connector. 3. CAUTION: Putting the large RCM electrical connector into the RCM on an angle can cause bad electrical connections and damage components. Position the large RCM electrical connector into the RCM. - CAUTION: Do not push the connector on to where the lever pivots and seats itself. Light pressure is needed to get the connector into position on the RCM before using the lever to fully seat the connector. With the large RCM electrical connector uniformly aligned to the RCM, lightly push in until a subtle audible click is heard and slight resistance is felt. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 1348 4. Connect the RCM electrical connector. - Pivot the connector position assurance lever toward the RCM, drawing the connector in to the RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place. 5. Connect the small RCM electrical connector. Vehicles with 60/40 front bench seat 6. WARNING: The tightening torque of the air bag restraints control module (RCM) to bracket retaining nuts is critical for correct system operation. Position the RCM to the bracket and install the 3 nuts. Tighten to 12 Nm (9 lb-ft). 7. Position the RCM top bracket and install the nuts. - Tighten to 12 Nm (9 lb-ft). Vehicles with a center console 8. Install the center console. Vehicles with 60/40 front bench seat 9. Install the 60 percent portion of the front bench seat. All vehicles 10. Repower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Control Module: > 05-22-17 > Nov > 05 > Restraints - Cannot Disable 'Belt Minder' Chime Seat Belt Control Module: Customer Interest Restraints - Cannot Disable 'Belt Minder' Chime TSB 05-22-17 11/14/05 INABILITY TO DISABLE THE SUPPLEMENTAL SAFETY BELT WARNING CHIME (BELTMINDER) FORD: 2006 Expedition LINCOLN: 2006 Navigator ISSUE Some 2006 Expedition/Navigator vehicles may exhibit an inability to disable the Belt Minder function following procedures listed in the Workshop Manual or the Owner Guide. The Belt Minder function operates normally, but can not be turned off (if desired by the customer). ACTION Replace the restraint control module (RCM), which includes software to disable the Belt Minder. Refer to Workshop Manual, Section 501-20B to replace the RCM. Then follow Workshop Manual, Section 413-09 or the Owner Guide procedure to disable the Belt Minder function. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052217A 2006 Expedition: Replace 1.0 Hrs. The Restraints Control Module Includes Time To Depower And Repower The Supplemental Restraints System And Disable The Beltminder (Do Not Use With 14056D, 14056D1B, 14056D1C, 14056D1XN, 14056DZR) 052217A 2006 Navigator: Replace 1.2 Hrs. The Restraints Control Module Includes Time To Depower And Repower The Supplemental Restraints System And Disable The Beltminder (Do Not Use With 14056D, 14056D1B, 14056D1C, 14056D1XN, 14056DZR) DEALER CODING CONDITION BASIC PART NO. CODE 14B321 42 OASIS CODES: 104000, 206000 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Control Module: > 05-22-17 > Nov > 05 > Restraints - Cannot Disable 'Belt Minder' Chime > Page 1357 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Control Module: > 05-22-17 > Nov > 05 > Restraints - Cannot Disable 'Belt Minder' Chime Seat Belt Control Module: All Technical Service Bulletins Restraints - Cannot Disable 'Belt Minder' Chime TSB 05-22-17 11/14/05 INABILITY TO DISABLE THE SUPPLEMENTAL SAFETY BELT WARNING CHIME (BELTMINDER) FORD: 2006 Expedition LINCOLN: 2006 Navigator ISSUE Some 2006 Expedition/Navigator vehicles may exhibit an inability to disable the Belt Minder function following procedures listed in the Workshop Manual or the Owner Guide. The Belt Minder function operates normally, but can not be turned off (if desired by the customer). ACTION Replace the restraint control module (RCM), which includes software to disable the Belt Minder. Refer to Workshop Manual, Section 501-20B to replace the RCM. Then follow Workshop Manual, Section 413-09 or the Owner Guide procedure to disable the Belt Minder function. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052217A 2006 Expedition: Replace 1.0 Hrs. The Restraints Control Module Includes Time To Depower And Repower The Supplemental Restraints System And Disable The Beltminder (Do Not Use With 14056D, 14056D1B, 14056D1C, 14056D1XN, 14056DZR) 052217A 2006 Navigator: Replace 1.2 Hrs. The Restraints Control Module Includes Time To Depower And Repower The Supplemental Restraints System And Disable The Beltminder (Do Not Use With 14056D, 14056D1B, 14056D1C, 14056D1XN, 14056DZR) DEALER CODING CONDITION BASIC PART NO. CODE 14B321 42 OASIS CODES: 104000, 206000 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Control Module: > 05-22-17 > Nov > 05 > Restraints - Cannot Disable 'Belt Minder' Chime > Page 1363 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1368 View 151-1 (Engine Compartment) The fuel pump relay is located in the Central Junction Box (CJB), in the engine compartment, RH side. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1369 C2163 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1370 Starter Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1371 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 1377 C1300 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 1378 Compressor/Pump Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 1379 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Locations Suspension Control Module: Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Locations > Page 1383 View 151-15 (LH A-Pillar) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Locations > Page 1384 Suspension Control Module: Diagrams C2131a C2131b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Locations > Page 1385 C2324a C2324b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Locations > Page 1386 Suspension Control Module: Service and Repair Air Suspension Control Module Removal and Installation 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable. 2. NOTE: The air suspension control module is mounted to the lower left side of the dash above the parking brake control. Disconnect the 2 air suspension control module electrical connectors. 3. Pull back the dash padding to expose the 2 module bracket nuts. 4. Remove the air suspension control module nuts and the air suspension control module. ^ To install, tighten to 8 Nm (71 inch lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Locations > Page 1387 5. NOTE: The air suspension control module is calibrated with information from the ride height sensors. A new or exchanged air suspension control module requires that the ride height adjustment calibration and pneumatic test be carried out. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Wheels and Tires > Tire Pressure Module > Component Information > Service and Repair Tire Pressure Module: Service and Repair Tire Pressure Monitoring System Module Removal and Installation CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: The tire pressure monitoring system (TPM's) is integral to the vehicle security module (VSM) and is not serviced separately. NOTE: A new VSM module is delivered in manufacturing mode with pre-set diagnostic trouble codes (DTC's). These DTC's require that a particular set of operations to be carried out in order to clear them and enable the module for normal operations. The pre-set DTC's are as follows: ^ B2477 - Module Configuration Failure/Mismatch ^ B2868 - Left Front Tire Pressure Sensor Fault ^ B2869 - Right Front Tire Pressure Sensor Fault ^ B2870 - Left Rear Tire Pressure Sensor Fault ^ B2871 - Right Rear Tire Pressure Sensor Fault ^ C2780 - ECU in Manufacturing Mode NOTE: A re-configured VSM may also set the above codes and will need to go through the same set of procedures as a new module to enable normal operation. 1. NOTE: The steps included in the VSM removal and installation process are critical to restoring vehicle security and tire pressure monitoring system operations and will permit a new or reconfigured module to operate as intended. Each step is designed to carry out a particular operation and clear the manufacturing mode DTC's. Once these DTC's are cleared, the new or reconfigured module will enter into normal operating mode. Remove the VSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair Control Module: Service and Repair Four-Wheel Drive (4WD) Control Module Removal and Installation NOTE: The Four Wheel Drive (4WD) control module is integral to the Powertrain Control Module (PCM) and is not serviced separately. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 Four Wheel Drive Selector Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 1400 View 151-1 (Engine Compartment) The transfercase Low to High and High to Low relays are located in the Auxiliary relay box 1 located in the engine compartment. LH side, front. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Transfer Case Low to High Relay C1129 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Transfer Case Low to High Relay > Page 1403 C1173 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Testing and Inspection > Transfer Case Low to High Relay Four Wheel Drive Selector Relay: Testing and Inspection Transfer Case Low to High Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Testing and Inspection > Transfer Case Low to High Relay > Page 1406 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Testing and Inspection > Transfer Case Low to High Relay > Page 1407 Four Wheel Drive Selector Relay: Testing and Inspection Transfer Case High to Low Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Testing and Inspection > Transfer Case Low to High Relay > Page 1408 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 1413 C2021 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 1414 Heated Glass Element Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 1415 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Accessory Delay Relay Power Window Relay: Locations Accessory Delay Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Accessory Delay Relay > Page 1420 View 151-1 (Engine Compartment) The accessory delay relay is located in the central junction box, in the engine compartment, RH side. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Accessory Delay Relay > Page 1421 Power Window Relay: Locations Quarter Window Open Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Accessory Delay Relay > Page 1422 View 151-21 (Right Rear) The quarter window open relay is located in the auxiliary relay box 2, behind trim panel, in loading space, RH side. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Accessory Delay Relay > Page 1423 Power Window Relay: Locations Quarter Window Close Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Accessory Delay Relay > Page 1424 View 151-21 (Right Rear) The quarter window close relay is located in the auxiliary relay box 2, behind trim panel, in loading space, RH side. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Quarter Window Open Relay C4175 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Quarter Window Open Relay > Page 1427 C4176 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Open Relay Power Window Relay: Testing and Inspection Quarter Window Open Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Open Relay > Page 1430 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Open Relay > Page 1431 Power Window Relay: Testing and Inspection Quarter Window Close Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Open Relay > Page 1432 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Inner/Outer Left View 151-19 (Left Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Inner/Outer Left > Page 1439 View 151-21 (Right Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Inner/Outer Left > Page 1440 View 151-21 (Right Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Radar Sensor C4191 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Radar Sensor > Page 1443 Parking Assist Distance Sensor: Diagrams Parking Aid Ultrasonic Sensor C4192 C4193 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Radar Sensor > Page 1444 C4009 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Radar Sensor > Page 1445 C4011 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Radar Sensor > Page 1446 Parking Assist Distance Sensor: Diagrams C4191 C4192 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Radar Sensor > Page 1447 C4193 C4009 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Radar Sensor > Page 1448 C4011 C4010 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Radar Sensor > Page 1449 C4012 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 1450 Parking Assist Distance Sensor: Service and Repair PARKING AID SENSOR Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 1451 Removal and Installation All vehicles 1. Remove the rear bumper cover. 2. Remove the nuts and the foam absorber from the bumper cover. 3. Remove the ultrasonic sensor(s). 1 Disconnect the electrical connector(s). 2 Release the locking tabs. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 1452 3 Remove the ultrasonic sensor(s). Navigator 4. Remove the radar sensor. 1 Disconnect the electrical connector. 2 Remove the two parking aid radar sensor nuts. 3 Remove the radar sensor. All vehicles 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Sensor > Component Information > Diagrams C2090 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations View 151-12 (Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 1459 Pedal Positioning Switch: Diagrams C2089 C2235 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 1460 Pedal Positioning Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 1461 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 1462 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Sensor > Component Information > Diagrams C2090 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations View 151-12 (Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 1470 Pedal Positioning Switch: Diagrams C2089 C2235 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 1471 Pedal Positioning Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 1472 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 1473 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side View 151-29 (Passenger Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side > Page 1478 View 151-28 (Driver Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side Power Door Lock Switch: Diagrams Door Lock Switch, Driver Side C505 C541 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side > Page 1481 Power Door Lock Switch: Diagrams Door Lock Switch, Passenger Side C605 C632 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 1482 Power Door Lock Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 1483 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations View 151-28 (Driver Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 1487 Power Mirror Switch: Diagrams C527 C577 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 1488 Power Mirror Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 1489 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 1490 Power Mirror Switch: Service and Repair EXTERIOR MIRROR CONTROL SWITCH Removal and Installation All vehicles 1. Remove the driver front door trim panel. Navigator 2. Depress the locking tabs and remove the exterior mirror control switch. Expedition Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 1491 3. Remove the exterior mirror control switch. 1 Depress the locking tabs. 2 Remove the exterior mirror control switch. All vehicles 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor View 151-26 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor > Page 1496 View 151-35 (Chassis, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor > Page 1497 View 151-36 (Chassis, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor > Page 1498 View 151-26 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor > Page 1499 View 151-26 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor C372 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 1502 C383 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 1503 C373 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 1504 C1151 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 1505 Power Seat Motor Position Sensor: Diagrams C372 C383 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 1506 C373 C1151 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 1507 C1153 C4084 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 1508 C3244 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left/Right View 151-21 (Right Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left/Right > Page 1513 View 151-26 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left/Right > Page 1514 View 151-27 (Passenger Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Left Power Seat Switch: Diagrams Left C352 C3016 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Left > Page 1517 Power Seat Switch: Diagrams Right C355 C3026 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Left > Page 1518 C4179 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Left > Page 1519 C4180 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat Power Seat Switch: Testing and Inspection Power Seat Switch, Left-6-Way Power Seat Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 1522 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 1523 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 1524 Power Seat Switch: Testing and Inspection Power Seat Switch, Left-8-Way Power Seat Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 1525 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 1526 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 1527 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 1528 Power Seat Switch: Testing and Inspection Power Seat Switch, Right-6-Way Power Seat Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 1529 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 1530 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 1531 Power Seat Switch: Testing and Inspection Power Seat Switch, Right-8-Way Power Seat Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 1532 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 1533 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 1534 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 1535 Power Seat Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 1536 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 1537 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 1538 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 1539 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 1540 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 1541 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 1542 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 1543 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 1544 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 1545 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 1546 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 1547 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 1548 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 1549 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 1550 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 1551 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 1552 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch - 8-Way Power Seat Switch: Service and Repair Seat Control Switch - 8-Way SEAT CONTROL SWITCH - 8-WAY Removal and Installation WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Driver side shown, passenger side similar. 1. Position the seat to gain access to all seat track-to-floor fasteners. 2. Depower the SRS. 3. Remove the 40 percent seat. 4. Pry and remove the seat control switch and power recline knobs. 5. Access and remove the cushion side shield front screw. 6. Pull out from the bottom and rear side of the cushion side shield to release the 3 retainer clips. 7. Disconnect the power lumbar and seat control switch electrical connectors and remove the cushion side shield. 8. Remove the 3 screws and remove the 8-way seat control switch. 9. To install, reverse the removal procedure. 10. Install the 40 percent seat. 11. Repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch - 8-Way > Page 1555 Power Seat Switch: Service and Repair Seat Control Switch - 6-Way SEAT CONTROL SWITCH - 6-WAY Removal and Installation WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Driver seat is shown, passenger is similar. 1. Position the seat to gain access to all seat track-to-floor fasteners. 2. Depower the SRS. 3. Remove the 40 percent seat. 4. From under the seat, disconnect the 6-way power seat switch electrical connector. 5. Remove the recliner handle screw cover, screw and recliner handle. 6. CAUTION: Use care when removing the lumbar knob. Using both hands, pull with even pressure on both sides of the knob to remove. Pull out to remove the manual lumbar knob. 7. Remove the cushion side shield screw from under the manual lumbar knob. 8. CAUTION: Use care not to scratch the side shield when removing the power seat knob. Pry the seat control switch knob off. 9. Access and remove the front cushion side shield screw. 10. Pull to release the center and rear retainers and remove the cushion side shield. 11. Remove the 2 seat control switch screws and remove the 6-way seat control switch from the cushion side shield. 12. To install, reverse the removal procedure. 13. Install the 40 percent seat. 14. Repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch - 8-Way > Page 1556 Power Seat Switch: Service and Repair Seat Control Switch - Third Row SEAT CONTROL SWITCH - THIRD ROW Removal and Installation 1. Partially remove the RH quarter trim panel for access to the third row power seat switch(es.). 2. Remove the one-way push nuts on the back side of the power seat switch bezel. 3. Disconnect the RH and LH third row seat control switch electrical connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch - 8-Way > Page 1557 4. Release the 4 locking tabs (2 shown) on the affected switch, and remove the switch. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations View 151-32 (Liftgate) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Page 1561 C4039 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D Technical Service Bulletin # 06-13-6 Date: 060710 A/C - Climate Controlled Seats DTC B272C or B272D TSB 06-13-6 07/10/06 DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-14-10 to update the Service Procedure. ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs) B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various sources, making them difficult to diagnose. ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT061306 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14C724 42 Disclaimer Section 1 SECTION 1 1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General Procedures; Supplemental Restraint System Depowering and Repowering. 2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a, C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1570 3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS fails when activated in the heat mode. a. If the time to failure is 5 seconds or less then, proceed to Section 2. b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section 3. c. If the time to failure is 40 seconds or greater, then, proceed to Section 4. NOTE THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4 THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED. THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK. Section 2 SECTION 2 (Seat Shuts Off In Less Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system. a. If there is an over-temp DTC present then go to Step 3. b. If no over-temp DTC is present then go to Step 6. 3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go to Step 4. b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11. c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair as needed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1571 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger cushion) Figure 1.) a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM. b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms? (1) If no, then replace TED. (2) If yes, go to Step 5. 5. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then go to Step 6. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to Step 12. b. If not then proceed to Step 7. 7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then proceed to Step 8. b. If no, then go to Step 9 in Section 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1572 8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) a. If plugged in, then proceed to Step 9. b. If not plugged in, then correct and proceed to Step 12. 9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM). (Figure 2) a. If it is open, then proceed to Step 10. b. If it is not open, then proceed to Step 11. 10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the harnesses). a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step 12. b. If the wire harnesses are good, then proceed to Step 11. 11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms (proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room temperature)? a. No, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. Yes, then replace the DCCSM and proceed to Step 12. 12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to customer. Section 3 SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B). a. If there is an over-temp DTC present, then continue to Step 3. b. If there is no over-temp DTC present, then continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1573 c. If CCS is now operable, then repower the SRS and return vehicle to customer. 3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If readings are hotter than room temperature, go to Step 4. b. If TED temperatures between Back and Cushion are 100 different, go to Step 12. c. If reading correctly then, proceed to Step 5. 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion). (Figure 1) a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on. (1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground. (2) If yes, fix the wiring, if no replace the DCCSM. b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms? (1) If yes, go to Step 5. (2) If no, then replace TED. (Figure 2) 5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, go to Step 6. b. If no, go to Step 7. 6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to Pin 2. a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM, otherwise replace the harness. Verify system now functions and return vehicle to customer. b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system now functions and return vehicle to customer. 7. Cycle ignition and enter into high cool mode. Does failure still occur? a. If no, proceed to Step 8. b. If yes, proceed to Step 13. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1574 8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED connector. NOTE DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE a. If voltage is not getting to the suspect TED, proceed to Step 9. b. If voltage is getting to the suspect TED, replace TED. 9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the module. (Figure 3) ^ Driver Cushion - Pin 9 ^ Driver Backrest - Pin 8 ^ Passenger Cushion - Pin 11 ^ Passenger Backrest - Pin 22 a. If no voltage is coming out of the module, then replace the module and continue to Step 13. b. If the correct voltage is coming out of the module, then continue to Step 10. 10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found, then continue to Step 11. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1575 11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2 volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5) 12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms (proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room temperature)? a. If no, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. If yes, then proceed to Step 13. 13. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1. b. Time to failure is not different than before, then continue to Step 14. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1576 14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7) a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1577 b. If there are no kinks or obstructions of the ducting then, continue to Step 16. 15. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 16. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1578 16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been obstructed or damaged or bunched in the cushion blocking air flow from the TED. a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 17. b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then replace the TED and continue to Step 17. 17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer. Section 4 SECTION 4 (Seat Shuts Off After More Than 40 Seconds) 1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected seat when a heating cycle is initiated. a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2. b. If the TEDs both increase temperature, then proceed to Step 3. 2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED that does not increase temperature from Step 1. a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed to Step 3. b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED, verify the fix and proceed to Step 6. 3. Check for any kinks or obstructions of the ducting from the fan to the TED. a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible otherwise replace the ducting and continue to Step 4. b. If there are no kinks or obstructions of the ducting, then continue to Step 5. 4. If CCS continues to be inoperable with DTC B272C/D code and Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1579 a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 5. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion alignment is incorrect. a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6. b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6. c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 6. d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a climate control seat, then replace the TED and continue to Step 6. 6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer. Section 5 SECTION 5 (Spread Terminal Fix Procedure) 1. Position the front passenger seat fully rearward and up. 2. Pull out and remove the seat track front cover. 3. Disconnect Connector C3265B 24-pin gray. (Figure 3). 4. Remove the red secondary wedge inside the connector. 5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3). NOTE DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG CAVITY. 6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the terminal) and bend the spring into the proper position (Figure 10). 7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the connector. 8. Reconnect C3265B to the dual climate control seat module. 9. Reinstall the seat track front cover. 10. Repower the SRS. Refer to WSM, Section 501-20B. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1580 11. Verify the climate control seat function, and recheck DTCs. 12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D Technical Service Bulletin # 06-13-6 Date: 060710 A/C - Climate Controlled Seats DTC B272C or B272D TSB 06-13-6 07/10/06 DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-14-10 to update the Service Procedure. ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs) B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various sources, making them difficult to diagnose. ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT061306 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14C724 42 Disclaimer Section 1 SECTION 1 1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General Procedures; Supplemental Restraint System Depowering and Repowering. 2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a, C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1586 3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS fails when activated in the heat mode. a. If the time to failure is 5 seconds or less then, proceed to Section 2. b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section 3. c. If the time to failure is 40 seconds or greater, then, proceed to Section 4. NOTE THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4 THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED. THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK. Section 2 SECTION 2 (Seat Shuts Off In Less Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system. a. If there is an over-temp DTC present then go to Step 3. b. If no over-temp DTC is present then go to Step 6. 3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go to Step 4. b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11. c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair as needed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1587 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger cushion) Figure 1.) a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM. b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms? (1) If no, then replace TED. (2) If yes, go to Step 5. 5. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then go to Step 6. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to Step 12. b. If not then proceed to Step 7. 7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then proceed to Step 8. b. If no, then go to Step 9 in Section 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1588 8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) a. If plugged in, then proceed to Step 9. b. If not plugged in, then correct and proceed to Step 12. 9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM). (Figure 2) a. If it is open, then proceed to Step 10. b. If it is not open, then proceed to Step 11. 10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the harnesses). a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step 12. b. If the wire harnesses are good, then proceed to Step 11. 11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms (proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room temperature)? a. No, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. Yes, then replace the DCCSM and proceed to Step 12. 12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to customer. Section 3 SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B). a. If there is an over-temp DTC present, then continue to Step 3. b. If there is no over-temp DTC present, then continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1589 c. If CCS is now operable, then repower the SRS and return vehicle to customer. 3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If readings are hotter than room temperature, go to Step 4. b. If TED temperatures between Back and Cushion are 100 different, go to Step 12. c. If reading correctly then, proceed to Step 5. 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion). (Figure 1) a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on. (1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground. (2) If yes, fix the wiring, if no replace the DCCSM. b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms? (1) If yes, go to Step 5. (2) If no, then replace TED. (Figure 2) 5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, go to Step 6. b. If no, go to Step 7. 6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to Pin 2. a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM, otherwise replace the harness. Verify system now functions and return vehicle to customer. b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system now functions and return vehicle to customer. 7. Cycle ignition and enter into high cool mode. Does failure still occur? a. If no, proceed to Step 8. b. If yes, proceed to Step 13. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1590 8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED connector. NOTE DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE a. If voltage is not getting to the suspect TED, proceed to Step 9. b. If voltage is getting to the suspect TED, replace TED. 9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the module. (Figure 3) ^ Driver Cushion - Pin 9 ^ Driver Backrest - Pin 8 ^ Passenger Cushion - Pin 11 ^ Passenger Backrest - Pin 22 a. If no voltage is coming out of the module, then replace the module and continue to Step 13. b. If the correct voltage is coming out of the module, then continue to Step 10. 10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found, then continue to Step 11. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1591 11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2 volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5) 12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms (proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room temperature)? a. If no, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. If yes, then proceed to Step 13. 13. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1. b. Time to failure is not different than before, then continue to Step 14. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1592 14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7) a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1593 b. If there are no kinks or obstructions of the ducting then, continue to Step 16. 15. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 16. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1594 16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been obstructed or damaged or bunched in the cushion blocking air flow from the TED. a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 17. b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then replace the TED and continue to Step 17. 17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer. Section 4 SECTION 4 (Seat Shuts Off After More Than 40 Seconds) 1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected seat when a heating cycle is initiated. a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2. b. If the TEDs both increase temperature, then proceed to Step 3. 2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED that does not increase temperature from Step 1. a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed to Step 3. b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED, verify the fix and proceed to Step 6. 3. Check for any kinks or obstructions of the ducting from the fan to the TED. a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible otherwise replace the ducting and continue to Step 4. b. If there are no kinks or obstructions of the ducting, then continue to Step 5. 4. If CCS continues to be inoperable with DTC B272C/D code and Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1595 a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 5. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion alignment is incorrect. a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6. b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6. c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 6. d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a climate control seat, then replace the TED and continue to Step 6. 6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer. Section 5 SECTION 5 (Spread Terminal Fix Procedure) 1. Position the front passenger seat fully rearward and up. 2. Pull out and remove the seat track front cover. 3. Disconnect Connector C3265B 24-pin gray. (Figure 3). 4. Remove the red secondary wedge inside the connector. 5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3). NOTE DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG CAVITY. 6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the terminal) and bend the spring into the proper position (Figure 10). 7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the connector. 8. Reconnect C3265B to the dual climate control seat module. 9. Reinstall the seat track front cover. 10. Repower the SRS. Refer to WSM, Section 501-20B. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1596 11. Verify the climate control seat function, and recheck DTCs. 12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D Technical Service Bulletin # 06-13-6 Date: 060710 A/C - Climate Controlled Seats DTC B272C or B272D TSB 06-13-6 07/10/06 DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-14-10 to update the Service Procedure. ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs) B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various sources, making them difficult to diagnose. ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT061306 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14C724 42 Disclaimer Section 1 SECTION 1 1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General Procedures; Supplemental Restraint System Depowering and Repowering. 2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a, C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1605 3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS fails when activated in the heat mode. a. If the time to failure is 5 seconds or less then, proceed to Section 2. b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section 3. c. If the time to failure is 40 seconds or greater, then, proceed to Section 4. NOTE THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4 THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED. THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK. Section 2 SECTION 2 (Seat Shuts Off In Less Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system. a. If there is an over-temp DTC present then go to Step 3. b. If no over-temp DTC is present then go to Step 6. 3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go to Step 4. b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11. c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair as needed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1606 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger cushion) Figure 1.) a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM. b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms? (1) If no, then replace TED. (2) If yes, go to Step 5. 5. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then go to Step 6. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to Step 12. b. If not then proceed to Step 7. 7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then proceed to Step 8. b. If no, then go to Step 9 in Section 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1607 8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) a. If plugged in, then proceed to Step 9. b. If not plugged in, then correct and proceed to Step 12. 9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM). (Figure 2) a. If it is open, then proceed to Step 10. b. If it is not open, then proceed to Step 11. 10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the harnesses). a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step 12. b. If the wire harnesses are good, then proceed to Step 11. 11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms (proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room temperature)? a. No, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. Yes, then replace the DCCSM and proceed to Step 12. 12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to customer. Section 3 SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B). a. If there is an over-temp DTC present, then continue to Step 3. b. If there is no over-temp DTC present, then continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1608 c. If CCS is now operable, then repower the SRS and return vehicle to customer. 3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If readings are hotter than room temperature, go to Step 4. b. If TED temperatures between Back and Cushion are 100 different, go to Step 12. c. If reading correctly then, proceed to Step 5. 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion). (Figure 1) a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on. (1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground. (2) If yes, fix the wiring, if no replace the DCCSM. b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms? (1) If yes, go to Step 5. (2) If no, then replace TED. (Figure 2) 5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, go to Step 6. b. If no, go to Step 7. 6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to Pin 2. a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM, otherwise replace the harness. Verify system now functions and return vehicle to customer. b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system now functions and return vehicle to customer. 7. Cycle ignition and enter into high cool mode. Does failure still occur? a. If no, proceed to Step 8. b. If yes, proceed to Step 13. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1609 8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED connector. NOTE DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE a. If voltage is not getting to the suspect TED, proceed to Step 9. b. If voltage is getting to the suspect TED, replace TED. 9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the module. (Figure 3) ^ Driver Cushion - Pin 9 ^ Driver Backrest - Pin 8 ^ Passenger Cushion - Pin 11 ^ Passenger Backrest - Pin 22 a. If no voltage is coming out of the module, then replace the module and continue to Step 13. b. If the correct voltage is coming out of the module, then continue to Step 10. 10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found, then continue to Step 11. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1610 11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2 volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5) 12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms (proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room temperature)? a. If no, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. If yes, then proceed to Step 13. 13. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1. b. Time to failure is not different than before, then continue to Step 14. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1611 14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7) a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1612 b. If there are no kinks or obstructions of the ducting then, continue to Step 16. 15. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 16. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1613 16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been obstructed or damaged or bunched in the cushion blocking air flow from the TED. a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 17. b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then replace the TED and continue to Step 17. 17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer. Section 4 SECTION 4 (Seat Shuts Off After More Than 40 Seconds) 1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected seat when a heating cycle is initiated. a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2. b. If the TEDs both increase temperature, then proceed to Step 3. 2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED that does not increase temperature from Step 1. a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed to Step 3. b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED, verify the fix and proceed to Step 6. 3. Check for any kinks or obstructions of the ducting from the fan to the TED. a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible otherwise replace the ducting and continue to Step 4. b. If there are no kinks or obstructions of the ducting, then continue to Step 5. 4. If CCS continues to be inoperable with DTC B272C/D code and Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1614 a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 5. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion alignment is incorrect. a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6. b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6. c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 6. d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a climate control seat, then replace the TED and continue to Step 6. 6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer. Section 5 SECTION 5 (Spread Terminal Fix Procedure) 1. Position the front passenger seat fully rearward and up. 2. Pull out and remove the seat track front cover. 3. Disconnect Connector C3265B 24-pin gray. (Figure 3). 4. Remove the red secondary wedge inside the connector. 5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3). NOTE DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG CAVITY. 6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the terminal) and bend the spring into the proper position (Figure 10). 7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the connector. 8. Reconnect C3265B to the dual climate control seat module. 9. Reinstall the seat track front cover. 10. Repower the SRS. Refer to WSM, Section 501-20B. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1615 11. Verify the climate control seat function, and recheck DTCs. 12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D Technical Service Bulletin # 06-13-6 Date: 060710 A/C - Climate Controlled Seats DTC B272C or B272D TSB 06-13-6 07/10/06 DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-14-10 to update the Service Procedure. ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs) B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various sources, making them difficult to diagnose. ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT061306 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14C724 42 Disclaimer Section 1 SECTION 1 1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General Procedures; Supplemental Restraint System Depowering and Repowering. 2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a, C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1621 3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS fails when activated in the heat mode. a. If the time to failure is 5 seconds or less then, proceed to Section 2. b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section 3. c. If the time to failure is 40 seconds or greater, then, proceed to Section 4. NOTE THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4 THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED. THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK. Section 2 SECTION 2 (Seat Shuts Off In Less Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system. a. If there is an over-temp DTC present then go to Step 3. b. If no over-temp DTC is present then go to Step 6. 3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go to Step 4. b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11. c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair as needed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1622 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger cushion) Figure 1.) a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM. b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms? (1) If no, then replace TED. (2) If yes, go to Step 5. 5. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then go to Step 6. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to Step 12. b. If not then proceed to Step 7. 7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then proceed to Step 8. b. If no, then go to Step 9 in Section 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1623 8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) a. If plugged in, then proceed to Step 9. b. If not plugged in, then correct and proceed to Step 12. 9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM). (Figure 2) a. If it is open, then proceed to Step 10. b. If it is not open, then proceed to Step 11. 10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the harnesses). a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step 12. b. If the wire harnesses are good, then proceed to Step 11. 11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms (proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room temperature)? a. No, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. Yes, then replace the DCCSM and proceed to Step 12. 12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to customer. Section 3 SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B). a. If there is an over-temp DTC present, then continue to Step 3. b. If there is no over-temp DTC present, then continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1624 c. If CCS is now operable, then repower the SRS and return vehicle to customer. 3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If readings are hotter than room temperature, go to Step 4. b. If TED temperatures between Back and Cushion are 100 different, go to Step 12. c. If reading correctly then, proceed to Step 5. 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion). (Figure 1) a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on. (1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground. (2) If yes, fix the wiring, if no replace the DCCSM. b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms? (1) If yes, go to Step 5. (2) If no, then replace TED. (Figure 2) 5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, go to Step 6. b. If no, go to Step 7. 6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to Pin 2. a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM, otherwise replace the harness. Verify system now functions and return vehicle to customer. b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system now functions and return vehicle to customer. 7. Cycle ignition and enter into high cool mode. Does failure still occur? a. If no, proceed to Step 8. b. If yes, proceed to Step 13. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1625 8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED connector. NOTE DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE a. If voltage is not getting to the suspect TED, proceed to Step 9. b. If voltage is getting to the suspect TED, replace TED. 9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the module. (Figure 3) ^ Driver Cushion - Pin 9 ^ Driver Backrest - Pin 8 ^ Passenger Cushion - Pin 11 ^ Passenger Backrest - Pin 22 a. If no voltage is coming out of the module, then replace the module and continue to Step 13. b. If the correct voltage is coming out of the module, then continue to Step 10. 10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found, then continue to Step 11. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1626 11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2 volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5) 12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms (proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room temperature)? a. If no, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. If yes, then proceed to Step 13. 13. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1. b. Time to failure is not different than before, then continue to Step 14. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1627 14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7) a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1628 b. If there are no kinks or obstructions of the ducting then, continue to Step 16. 15. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 16. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1629 16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been obstructed or damaged or bunched in the cushion blocking air flow from the TED. a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 17. b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then replace the TED and continue to Step 17. 17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer. Section 4 SECTION 4 (Seat Shuts Off After More Than 40 Seconds) 1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected seat when a heating cycle is initiated. a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2. b. If the TEDs both increase temperature, then proceed to Step 3. 2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED that does not increase temperature from Step 1. a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed to Step 3. b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED, verify the fix and proceed to Step 6. 3. Check for any kinks or obstructions of the ducting from the fan to the TED. a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible otherwise replace the ducting and continue to Step 4. b. If there are no kinks or obstructions of the ducting, then continue to Step 5. 4. If CCS continues to be inoperable with DTC B272C/D code and Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1630 a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 5. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion alignment is incorrect. a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6. b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6. c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 6. d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a climate control seat, then replace the TED and continue to Step 6. 6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer. Section 5 SECTION 5 (Spread Terminal Fix Procedure) 1. Position the front passenger seat fully rearward and up. 2. Pull out and remove the seat track front cover. 3. Disconnect Connector C3265B 24-pin gray. (Figure 3). 4. Remove the red secondary wedge inside the connector. 5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3). NOTE DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG CAVITY. 6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the terminal) and bend the spring into the proper position (Figure 10). 7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the connector. 8. Reconnect C3265B to the dual climate control seat module. 9. Reinstall the seat track front cover. 10. Repower the SRS. Refer to WSM, Section 501-20B. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 1631 11. Verify the climate control seat function, and recheck DTCs. 12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations View 151-28 (Driver Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 1635 C503 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 1636 Seat Memory Switch: Testing and Inspection SWITCH - MEMORY SET Memory Set Switch Remove the memory set switch. Measure the resistance between the indicated terminals while pressing the requested switches. The resistance should be less than 5 ohms for each switch position. If the resistance is not less than 5 ohms for each switch, install a new switch; otherwise, return to the calling pinpoint test. NOTE: Refer to multimeter user's manual for testing diodes. To check the memory set switch LED, connect the positive meter lead to terminal 7 and the negative lead to terminal 1. 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, install a new switch; otherwise, return to the calling pinpoint test. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations View 151-23 (Roof) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 1640 Sunroof / Moonroof Switch: Diagrams C912 C9001 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 1641 Sunroof / Moonroof Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 1642 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Liftgate Fork Bolt/Detent Switch View 151-32 (Liftgate) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Liftgate Fork Bolt/Detent Switch > Page 1647 View 151-32 (Liftgate) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Liftgate Fork Bolt/Detent Switch > Page 1648 View 151-23 (Roof) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Liftgate Fork Bolt/Detent Switch C4190 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Liftgate Fork Bolt/Detent Switch > Page 1651 C4187 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Liftgate Fork Bolt/Detent Switch > Page 1652 C9000 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump Switch, Seats > Component Information > Locations > Lumbar Adjust Switch, Left Front View 151-26 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump Switch, Seats > Component Information > Locations > Lumbar Adjust Switch, Left Front > Page 1657 View 151-27 (Passenger Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump Switch, Seats > Component Information > Diagrams > Lumbar Adjust Switch, Right Front C331 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump Switch, Seats > Component Information > Diagrams > Lumbar Adjust Switch, Right Front > Page 1660 C361 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump Switch, Seats > Component Information > Diagrams > Page 1661 Vacuum/Pressure Pump Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump Switch, Seats > Component Information > Diagrams > Page 1662 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump Switch, Seats > Component Information > Diagrams > Page 1663 Vacuum/Pressure Pump Switch: Service and Repair LUMBAR CONTROL SWITCH Removal and Installation WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Position the seat to gain access to all seat track-to-floor fasteners. 2. Depower the SRS. 3. Remove the 40 percent seat. 4. Access and remove the cushion side shield front screw. 5. Pull out from the bottom and rear side of cushion side shield to release the 3 retainer clips. 6. Disconnect the power lumbar switch and 8-way power seat switch electrical connectors. 7. Pinch retainer in and push from the rear of power lumbar switch to remove the switch from the side shield. 8. To install, reverse the removal procedure. 9. Install the 40 percent seat. 10. Repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Service and Repair ABS Sensor Block: Service and Repair Stability Control Sensor Cluster Removal and Installation NOTE: The lateral and longitudinal accelerometer and the roll rate sensor are located within the yaw rate sensor, stability control sensor cluster. 1. Remove the front floor console. For additional information, refer to Console. 2. Disconnect the stability control sensor cluster electrical connector. 3. Remove the 2 bolts and the stability control sensor cluster. ^ To install, tighten to 12 Nm (9 ft. lbs.). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations > Page 1671 C149 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 1675 C124 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 1676 Brake Fluid Level Sensor/Switch: Description and Operation Hydraulic Brake Actuation The brake pedal is connected to the power brake booster, which is connected to the brake master cylinder. The brake pedal is either fixed or adjustable; 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 front disc brake calipers and the rear disc brake calipers. The front disc brake caliper pistons are forced outward against the brake pads and contact the braking surface of the brake discs. 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. When the brake pedal is released, the pressure is relieved, returning the brake caliper pistons and the brake pads to the released 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. Brake Master Cylinder The brake master cylinder is a dual-piston type. The brake master cylinder is assisted by a power brake booster. These 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. Brake Fluid Level Warning Switch 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. Tubes and Hoses CAUTION: Only authorized inlet hydraulic brake tubes should be used. These tubes are of a specific design and new authorized parts only should be installed. Steel tubing with flex hoses are used in the hydraulic tubes between the brake master cylinder and the hydraulic control unit (HCU). Steel tubing is used between the HCU and the front and rear hoses. Double flared brake tubing provides 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Primary Brake Pressure Sensor View 151-1 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Primary Brake Pressure Sensor > Page 1681 View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Diagrams > Primary Brake Pressure Sensor C147 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Diagrams > Primary Brake Pressure Sensor > Page 1684 C148 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Service and Repair Lateral Accelerometer: Service and Repair Stability Control Sensor Cluster Removal and Installation NOTE: The lateral and longitudinal accelerometer and the roll rate sensor are located within the yaw rate sensor, stability control sensor cluster. 1. Remove the front floor console. For additional information, refer to Console. 2. Disconnect the stability control sensor cluster electrical connector. 3. Remove the 2 bolts and the stability control sensor cluster. ^ To install, tighten to 12 Nm (9 ft. lbs.). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Service and Repair Parking Brake Release Switch: Service and Repair Parking Brake Release Switch NOTE: Floor shift shown, column shift similar. Removal and Installation Column shift (Expedition only) 1. NOTE: The parking brake release switch is located on the steering column. It is serviced as an assembly with the brake shift interlock. Remove the brake shift interlock/park brake release switch assembly. Floor shift 2. Remove the floor shift selector lever. 3. Disconnect the parking brake release switch electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Service and Repair > Page 1691 4. Remove the 2 parking brake release switch screws and remove the switch. All vehicles 5. To install, reverse the removal procedure. ^ Make sure the switch is correctly aligned with the extension on the shifter before installing the screws. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations View 151-15 (LH A-Pillar) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 1695 C2015 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Service and Repair Steering Angle Sensor: Service and Repair Steering Wheel Rotation Sensor Removal and Installation 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the steering wheel rotation sensor electrical connector. 3. Remove the 2 bolts and the steering wheel rotation sensor. ^ To install, tighten to 4 Nm (35 inch lbs.). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations View 151-24 (Center Console) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 1702 C280 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Right Front View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Right Front > Page 1707 View 151-1 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Right Front > Page 1708 View 151-36 (Chassis, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 1711 C440 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 1712 C160 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 1713 C426 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Front Wheel Speed Sensor - Front Removal and Installation 1. NOTE: If equipped, turn the air suspension switch to the OFF position. With the vehicle in NEUTRAL, position it on a hoist 2. Disconnect the wheel speed sensor electrical connector. 3. Remove the wheel speed sensor harness retainer bolt and detach the retainers. ^ To install, tighten to 12 Nm (9 ft. lbs.). 4. CAUTION: Do not allow the caliper to hang from the brake hose or damage to the hose can result. Remove the 2 caliper anchor bolts and position the caliper, pads and anchor plate aside. ^ Support the caliper with mechanic's wire. ^ To install, tighten to 200 Nm (148 ft. lbs.). 5. Remove the brake disc. 6. Remove the front wheel speed sensor bolt and the sensor. ^ To install, tighten to 18 Nm (13 ft. lbs.). 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 1716 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Rear Wheel Speed Sensor - Rear Removal and Installation 1. Remove the parking brake shoes. 2. Disconnect the wheel speed sensor harness from the retaining clips. 3. Remove the rear wheel speed sensor bolt and the sensor. ^ To install, tighten to 18 Nm (13 ft. lbs.). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations View 151-12 (Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 1720 C245 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 1721 Yaw Rate Sensor: Service and Repair Stability Control Sensor Cluster Removal and Installation NOTE: The lateral and longitudinal accelerometer and the roll rate sensor are located within the yaw rate sensor, stability control sensor cluster. 1. Remove the front floor console. For additional information, refer to Console. 2. Disconnect the stability control sensor cluster electrical connector. 3. Remove the 2 bolts and the stability control sensor cluster. ^ To install, tighten to 12 Nm (9 ft. lbs.). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Radiator Cooling Fan Speed Sensor > Component Information > Description and Operation Radiator Cooling Fan Speed Sensor: Description and Operation FAN SPEED SENSOR (FSS) Cooling Fan Clutch With Fan Speed Sensor (FSS) The FSS is a Hall-effect sensor that measures the cooling fan clutch speed by generating a waveform with a frequency proportional to the fan speed. If the cooling fan clutch is moving at a relatively low speed, the sensor produces a signal with a low frequency. As the cooling fan clutch speed increases, the sensor generates a signal with a higher frequency. The powertrain control module (PCM) uses the frequency signal generated by the FSS as a feedback for closed loop control of the cooling fan clutch. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 1730 C107 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation > CHT Sensor Engine Temperature Sensor: Description and Operation CHT Sensor The CHT sensor: ^ is mounted into the wall of the cylinder head and is not connected to any coolant passages. ^ sends the PCM a signal indicating cylinder head temperature. ^ if the temperature exceeds approximately 121 °C (250°F), the PCM disables half of the fuel injectors at a time. The PCM will alternate which fuel injectors are disabled every 32 engine cycles. The cylinders that are not being fuel injected act as air pumps to aid in engine cooling. ^ if the temperature exceeds approximately 166°C (330°F), the PCM disables all of the fuel injectors until the engine temperature drops below approximately 1 54°C (31 0°F). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation > CHT Sensor > Page 1733 Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical Cylinder Head Temperature (CHT) Sensor The CHT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. The CHT sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM initiates a fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern such as low coolant or coolant loss could cause an overheating condition. As a result damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation > Page 1734 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR Removal and Installation 1. Remove the intake manifold. 2. Disconnect the cylinder head temperature (CHT) sensor jumper harness electrical connector. 3. Remove and discard the CHT sensor. - To install, tighten to 10 Nm (89 lb-in). - Coat the CHT sensor threads with high temperature nickel anti-seize lubricant prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch View 151-1 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch > Page 1740 View 151-10 (behind Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch C277 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch > Page 1743 C278 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Brake Pedal Position (BPP) Switch Brake Switch (Cruise Control): Description and Operation Brake Pedal Position (BPP) Switch BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - BPP switch is hardwired to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - BPP switch is hardwired to the Anti-Lock Brake System (ABS) Module, Lighting Control Module (LCM), or Rear Electronic Module (REM), the BPP signal is then broadcast over the network to be received by the PCM. - BPP switch is hardwired to the anti-lock brake system (ABS) traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Brake Pedal Position (BPP) Switch > Page 1746 Brake Switch (Cruise Control): Description and Operation Brake Pedal Switch (BPS)/Brake Deactivator Switch BRAKE PEDAL SWITCH (BPS)/BRAKE DEACTIVATOR SWITCH The BPS, also called the brake deactivator switch, is for vehicle speed control deactivation. A normally closed switch supplies battery positive voltage (B+) to the PCM when the brake pedal is not applied. When the brake pedal is applied, the normally closed switch opens and power is removed from the PCM. On some applications the normally closed BPS, along with the normally open BPP switch, are used for a brake rationality test within the PCM. The PCM misfire monitor profile learn function may be disabled if a brake switch concern occurs. If one or both brake pedal inputs to the PCM is not changing states when they were expected to, a diagnostic trouble code is set by the PCM strategy. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Page 1747 Brake Switch (Cruise Control): Service and Repair SPEED CONTROL DEACTIVATOR SWITCH Removal 1. NOTE: The speed control deactivator switch can only be adjusted once. If further adjusting is necessary, install a new switch. Remove the speed control deactivator switch. 1 Disconnect the electrical connector. 2 Rotate the deactivator switch counterclockwise 45 degrees and remove the switch. Installation All vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Page 1748 1. Release the plunger lock (if equipped). - Turn the lock knob counterclockwise until the first click is felt. 2. Fully apply the brake pedal 3. Install the speed control deactivator switch. 1 Position the deactivator switch in the bracket and rotate it clockwise 45 degrees. 2 Connect the electrical connector. Vehicles equipped with a locking tab 4. NOTE: There should be an extra click heard when tugging on the brake pedal. Slowly release the brake pedal and tug it moderately once the pedal reaches the rest position. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Description and Operation Clutch Switch: Description and Operation CLUTCH PEDAL POSITION (CPP) SWITCH Typical Clutch Pedal Position (CPP) Switch The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine load. The PCM uses the load information for mass air flow and fuel calculations. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair Cruise Control Switch: Service and Repair SPEED CONTROL SWITCH Removal and Installation All vehicles 1. Remove the driver air bag module. Expedition 2. Remove the 2 screws and the speed control switch. - Disconnect the electrical connector. Navigator 3. Remove the horn switch. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Page 1755 1 Disconnect the electrical connector. 2 Remove the 4 bolts. 4. Remove the speed control switch. 1 Disconnect the wiring harness locators. 2 Remove the 4 screws. To install, tighten to 7 Nm (62 lb-in). All vehicles 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1760 C103 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair ENGINE OIL PRESSURE (EOP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Disconnect the engine oil pressure (EOP) sensor electrical connector. 4. Remove the EOP sensor. - To install, tighten to 21 Nm (15 lb-ft). 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Description and Operation Oil Temperature Sensor/Switch: Description and Operation ENGINE OIL TEMPERATURE (EOT) SENSOR Typical Engine Oil Temperature (EOT) Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system. The PCM can use the EOT sensor input to determine the following: - On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM begins reducing power by disabling engine cylinders. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations View 151-1 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 1771 C132 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 1772 Ambient Temperature Sensor Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 1773 Ambient Temperature Sensor / Switch HVAC: Service and Repair AMBIENT AIR TEMPERATURE SENSOR Removal and Installation Expedition 1. Remove the upper radiator sight shield. All vehicles 2. Detach and disconnect the ambient temperature sensor electrical connector. 3. Remove the ambient air temperature sensor. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service and Repair > Blower Motor Switch Blower Motor Switch: Service and Repair Blower Motor Switch BLOWER MOTOR SWITCH Removal and Installation 1. Remove the climate control assembly. 2. Pull and remove the blower motor switch knob. 3. Release the 3 clips and remove the blower motor switch. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service and Repair > Blower Motor Switch > Page 1778 Blower Motor Switch: Service and Repair Blower Motor Speed Control BLOWER MOTOR SPEED CONTROL Removal and Installation 1. Remove the RH lower instrument panel insulator. 2. Disconnect the blower motor speed control electrical connector. 3. Remove the blower motor speed control screw. 4. Remove the blower motor speed control. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations View 151-12 (Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Diagrams > In-Vehicle Temperature Sensor C233 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Diagrams > In-Vehicle Temperature Sensor > Page 1784 C2247 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Diagrams > Page 1785 In-Vehicle Temperature Sensor Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > In-Vehicle Temperature Sensor Cabin Temperature Sensor / Switch: Service and Repair In-Vehicle Temperature Sensor IN-VEHICLE TEMPERATURE SENSOR Removal and Installation 1. Remove the instrument cluster finish panel. 2. Disconnect the aspirator hose and the in-vehicle temperature sensor electrical connector. 3. Remove the in-vehicle temperature sensor screws. 4. Remove the in-vehicle temperature sensor. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > In-Vehicle Temperature Sensor > Page 1788 Cabin Temperature Sensor / Switch: Service and Repair In-Vehicle Temperature and Humidity Sensor IN-VEHICLE TEMPERATURE AND HUMIDITY SENSOR Removal and Installation 1. Remove the in-vehicle temperature and humidity sensor trim cover. - Disconnect the electrical connector and aspirator tube. 2. Remove the 2 in-vehicle temperature and humidity sensor screws. 3. Remove the in-vehicle temperature and humidity sensor. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation Evaporator Temperature Sensor / Switch: Description and Operation AIR CONDITIONING EVAPORATOR TEMPERATURE (ACET) SENSOR A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance The ACET sensor measures the evaporator air discharge temperature. The ACET sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The PCM sources a low current 5 volts on the ACET circuit. With SIG RTN also connected to the ACET sensor, the varying resistance affects the voltage drop across the sensor terminals. As A/C evaporator air temperature changes, the varying resistance of the ACET sensor changes the voltage the PCM detects. The ACET sensor is used to more accurately control A/C clutch cycling, improve defrost/demist performance, and reduce A/C clutch cycling. NOTE: These values can vary 15 percent due to sensor and VREF variations. Voltage values were calculated for VREF equals 5.0 volts. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Page 1792 Evaporator Temperature Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) EVAPORATOR DISCHARGE AIR TEMPERATURE SENSOR Removal and Installation 1. Lower the glove compartment. 2. Remove the evaporator discharge air temperature sensor screw. 3. Disconnect the evaporator discharge air temperature sensor electrical connector. 4. Carefully pry the evaporator discharge air temperature sensor probe out of the heater core and evaporator core housing. 5. Remove the evaporator discharge air temperature sensor. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Humidity Sensor > Component Information > Diagrams C2247 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Humidity Sensor > Component Information > Diagrams > Page 1796 Humidity Sensor: Service and Repair IN-VEHICLE TEMPERATURE AND HUMIDITY SENSOR Removal and Installation 1. Remove the in-vehicle temperature and humidity sensor trim cover. - Disconnect the electrical connector and aspirator tube. 2. Remove the 2 in-vehicle temperature and humidity sensor screws. 3. Remove the in-vehicle temperature and humidity sensor. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1801 C1078 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1805 C130 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations View 151-10 (behind Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 1809 C286 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair Dimmer Switch: Service and Repair INSTRUMENT PANEL DIMMER SWITCH Removal and Installation 1. Remove the instrument panel finish panel. - Disconnect the electrical connectors. 2. Press the tabs and remove the instrument panel dimmer switch. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear View 151-30 (Left Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 1818 View 151-28 (Driver Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 1819 View 151-29 (Passenger Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 1820 View 151-31 (Right Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 1821 View 151-32 (Liftgate) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch C479 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 1824 C526 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 1825 C602 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 1826 C715 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 1827 C820 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 1828 Door Switch: Service and Repair DOOR AJAR SWITCH Removal and Installation 1. Remove the door lock actuator. 2. Release the locking tab and remove the door ajar switch. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump (FP) Module Fuel Gauge Sender: Description and Operation Fuel Pump (FP) Module FUEL PUMP (FP) MODULE Mechanical Returnless Fuel Pump Module (FPM) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump (FP) Module > Page 1833 Electronic Returnless Fuel Pump Module (FPM) The FP module is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump (FP) Module > Page 1834 Fuel Gauge Sender: Description and Operation Fuel Pump Module and Reservoir FUEL PUMP MODULE AND RESERVOIR Fuel Pump Module And Reservoir The fuel pump module is mounted inside the fuel tank in a reservoir. The pump has a discharge check valve that maintains the system pressure after the ignition key has been turned off to minimize starting concerns. The reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low tank fill levels. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 1835 Fuel Gauge Sender: Service and Repair FUEL PUMP MODULE Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 1836 Part 2 Exploded View Special Tool(s) Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 1837 Removal and Installation WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. 1. Remove the fuel tank. 2. Disconnect the fuel and vapor tubes from the fuel pump module. 3. Using the special tool, remove the fuel pump lock ring. 4. CAUTION: Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 1838 - Note the location of the fuel pump alignment tabs. - Carefully remove the fuel pump assembly to avoid damaging the fuel level sensor. Remove the fuel pump module assembly. Remove and discard the O-ring seal. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations View 151-15 (LH A-Pillar) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 1842 C2015 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Service and Repair Ambient Light Sensor: Service and Repair LIGHT SENSOR Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Service and Repair > Page 1847 Removal and Installation Expedition 1. Remove the light sensor and bezel as an assembly from the defroster grille. - Disconnect the electrical connector. 2. Remove the 2 screws and the light sensor. Navigator 3. Remove the defroster grille. 4. Remove the 2 screws and the light sensor. - Disconnect the electrical connector. All vehicles 5. To install, reverse the removal procedure Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1851 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1852 C167 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations View 151-10 (behind Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 1856 C278 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 1857 Brake Light Switch: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - BPP switch is hardwired to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - BPP switch is hardwired to the Anti-Lock Brake System (ABS) Module, Lighting Control Module (LCM), or Rear Electronic Module (REM), the BPP signal is then broadcast over the network to be received by the PCM. - BPP switch is hardwired to the anti-lock brake system (ABS) traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 1858 Brake Light Switch: Service and Repair STOPLAMP SWITCH Removal and Installation 1. Disconnect the stoplamp switch electrical connector. 2. Remove the self-locking pin. 3. Remove the stoplamp switch from the brake booster push rod and the brake pedal assembly. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear View 151-30 (Left Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 1863 View 151-28 (Driver Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 1864 View 151-29 (Passenger Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 1865 View 151-31 (Right Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 1866 View 151-32 (Liftgate) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch C479 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 1869 C526 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 1870 C602 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 1871 C715 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 1872 C820 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 1873 Door Switch: Service and Repair DOOR AJAR SWITCH Removal and Installation 1. Remove the door lock actuator. 2. Release the locking tab and remove the door ajar switch. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection Hazard Warning Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 1877 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 1878 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations View 151-14 (Steering Column) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 1882 Headlamp Dimmer Switch: Diagrams C202a C202b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 1883 C202c Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 1884 Headlamp Dimmer Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 1885 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations View 151-12 (Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 1889 Headlamp Switch: Diagrams C205a C205b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 1890 C205c Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Testing and Inspection > Main Light Switch, Exterior Lamps Headlamp Switch: Testing and Inspection Main Light Switch, Exterior Lamps Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Testing and Inspection > Main Light Switch, Exterior Lamps > Page 1893 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Testing and Inspection > Main Light Switch, Exterior Lamps > Page 1894 Headlamp Switch: Testing and Inspection Main Light Switch, Interior Lamps Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Testing and Inspection > Main Light Switch, Exterior Lamps > Page 1895 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Testing and Inspection > Page 1896 Headlamp Switch: Service and Repair HEADLAMP SWITCH Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Testing and Inspection > Page 1897 Removal and Installation Expedition 1. CAUTION: Cover the end of the tool with tape to prevent damage to the trim panel. NOTE: Use a thin-bladed tool to remove the headlamp switch bezel assembly. Remove the headlamp switch and bezel assembly. Disconnect the electrical connectors. Navigator 2. Remove the instrument panel finish panel. 3. NOTE: Release the tabs to remove the headlamp switch. Remove the 2 screws and the headlamp switch. All vehicles 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 INTERIOR LAMP SWITCH Removal and Installation 1. Remove the door trim panel. 2. Remove the interior lamp switch. 1 Disconnect the electrical connector. 2 Rotate the interior lamp switch one-quarter turn counterclockwise and remove. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations View 151-14 (Steering Column) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 1904 Turn Signal Switch: Diagrams C202a C202b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 1905 C202c Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion Turn Signal Switch: Testing and Inspection Multifunction Switch, Lamp Portion Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion > Page 1908 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion > Page 1909 Turn Signal Switch: Testing and Inspection Multifunction Switch, Turn Portion Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion > Page 1910 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion > Page 1911 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 1912 Turn Signal Switch: Service and Repair Steering Column Multifunction Switch Removal and Installation Steering Column Steering Column 1. Remove the steering wheel. 2. NOTE: Lower tilt release handle to access the second screw. Remove the lower steering column shroud. ^ Remove the screws. 3. NOTE: The screw is located behind the multi-function switch. Remove the screw and the upper steering column shroud. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 1913 4. Remove the bolt, push the release and raise the switch. 5. NOTE: A small screwdriver will be required to depress the connector release tab on connector number 2. Remove the multi-function switch. ^ Disconnect the 3 multi-function switch electrical connectors. ^ Remove the switch. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1919 C2040 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1920 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The APP sensor is an input to the powertrain control module (PCM) and is used to determine the torque demand. There are 3 pedal position signals in the sensor. Signal 1, APPS1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, APPS2 and APPS3, both have a positive slope (increasing angle, increasing voltage). During normal operation APPS1 is used as the indication of pedal position by the strategy. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. There are 2 reference voltage circuits and 2 signal return circuits for the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 1924 C1454 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 1925 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW (MAF) SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT Sensor Wire Where Applicable) Terminals Typical Mass Air Flow (MAF) Sensor Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 1926 Typical Drop-in Mass Air Flow (MAF) Sensor The MAF sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above the ambient temperature as measured by a constant cold wire. If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the mass air flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. Most MAF sensors have integrated bypass technology (IBT) with an integrated intake air temperature (IAT) sensor. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 1927 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the mass air flow (MAF) sensor electrical connector. 3. Remove the 2 bolts and the MAF sensor. - To install, tighten to 7 Nm (62 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1 C1366 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1 > Page 1933 C1367 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 1934 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR Typical Synchronizer Hall-Effect CMP Sensor Typical Variable Reluctance CMP Sensor The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston No. 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to select the correct ignition coil to fire. Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor and the 2-pin connector variable reluctance type sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 1935 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the camshaft position (CMP) sensor electrical connector. 3. Remove the bolt and the CMP sensor. Discard the O-ring seal. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Description and Operation Clutch Switch: Description and Operation CLUTCH PEDAL POSITION (CPP) SWITCH Typical Clutch Pedal Position (CPP) Switch The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine load. The PCM uses the load information for mass air flow and fuel calculations. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1942 C101 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1943 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Typical Crankshaft Position (CKP) Sensor The CKP sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L 10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1944 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the accessory drive belt. 4. Disconnect the A/C compressor electrical connector. 5. Remove the 3 bolts and position the A/C compressor aside. - To install, tighten to 25 Nm (18 lb-ft). 6. Disconnect the crankshaft position (CKP) sensor electrical connector. 7. Remove the bolt and the CKP sensor. Discard the O-ring seal. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the new O-ring seal with clean engine oil prior to installation. 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 1948 C107 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > CHT Sensor Engine Temperature Sensor: Description and Operation CHT Sensor The CHT sensor: ^ is mounted into the wall of the cylinder head and is not connected to any coolant passages. ^ sends the PCM a signal indicating cylinder head temperature. ^ if the temperature exceeds approximately 121 °C (250°F), the PCM disables half of the fuel injectors at a time. The PCM will alternate which fuel injectors are disabled every 32 engine cycles. The cylinders that are not being fuel injected act as air pumps to aid in engine cooling. ^ if the temperature exceeds approximately 166°C (330°F), the PCM disables all of the fuel injectors until the engine temperature drops below approximately 1 54°C (31 0°F). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > CHT Sensor > Page 1951 Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical Cylinder Head Temperature (CHT) Sensor The CHT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. The CHT sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM initiates a fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern such as low coolant or coolant loss could cause an overheating condition. As a result damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > Page 1952 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR Removal and Installation 1. Remove the intake manifold. 2. Disconnect the cylinder head temperature (CHT) sensor jumper harness electrical connector. 3. Remove and discard the CHT sensor. - To install, tighten to 10 Nm (89 lb-in). - Coat the CHT sensor threads with high temperature nickel anti-seize lubricant prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation FUEL LEVEL INPUT (FLI) NOTE: The Ford GT uses a piezoelectric sonar type fuel level sensor. The sensor is located in the tank and the sensor signal is provided as a communications network message by the instrument cluster to the PCM. The FLI is either a hard wire signal input to the PCM from the fuel pump (FP) module or a communications network message. Most vehicle applications use a potentiometer type FLI sensor connected to a float in the FP module to determine fuel level. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 1956 Fuel Level Sensor: Service and Repair FUEL PUMP MODULE Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 1957 Part 2 Exploded View Special Tool(s) Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 1958 Removal and Installation WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. 1. Remove the fuel tank. 2. Disconnect the fuel and vapor tubes from the fuel pump module. 3. Using the special tool, remove the fuel pump lock ring. 4. CAUTION: Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 1959 - Note the location of the fuel pump alignment tabs. - Carefully remove the fuel pump assembly to avoid damaging the fuel level sensor. Remove the fuel pump module assembly. Remove and discard the O-ring seal. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE (FTP) SENSOR Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The FTP sensor or in-line FTP sensor is used to measure the fuel tank pressure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Page 1963 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR Removal and Installation 1. Remove the fuel tank. 2. Disconnect the fuel vapor tube quick connect couplings from the fuel vapor/grade vent valves. 3. Disconnect the fuel vapor tube quick connect couplings from the fuel pump module. 4. Remove the fuel pressure sensor tube assembly. 5. To install, reverse the removal procedure. - Leak test the system. See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Evaporative Emission System Leak Test - Carry out the evaporative emission repair verification drive cycle. See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Evaporative Emission Repair Verification Drive Cycle Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 1967 C1454 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 1968 Intake Air Temperature Sensor: Description and Operation INTAKE AIR TEMPERATURE (IAT) SENSOR Typical Stand-Alone/Non-Integrated Intake Air Temperature (IAT) Sensors Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into A Drop-in Or Flange-type MAF Sensor The IAT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 1969 fuel, spark, and air flow. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Currently there are 2 design types of IAT sensors used, a stand-alone/non-integrated type and a integrated type. Both types function the same, however the integrated type is incorporated into the mass air flow (MAF) sensor instead of being a stand alone sensor. Supercharged vehicles use 2 IAT sensors. Both sensors are thermistor type devices and operate as described. However, one is located before the supercharger at the air cleaner for standard OBD/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 C109 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 1975 C108 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 1976 Knock Sensor: Description and Operation KNOCK SENSOR (KS) Two Types Of Knock Sensor (KS) The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 1977 Knock Sensor: Service and Repair KNOCK SENSOR (KS) Removal and Installation 1. Remove the intake manifold. 2. Disconnect the knock sensor (KS) electrical connectors. 3. Remove the 2 bolts and the 2 knock sensors. - To install, tighten to 20 Nm (15 lb-ft). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair ENGINE OIL PRESSURE (EOP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Disconnect the engine oil pressure (EOP) sensor electrical connector. 4. Remove the EOP sensor. - To install, tighten to 21 Nm (15 lb-ft). 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations > Page 1984 C104 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations > Page 1985 Oil Temperature Sensor For ECM: Description and Operation ENGINE OIL TEMPERATURE (EOT) SENSOR Typical Engine Oil Temperature (EOT) Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system. The PCM can use the EOT sensor input to determine the following: - On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM begins reducing power by disabling engine cylinders. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations > Page 1986 Oil Temperature Sensor For ECM: Service and Repair OIL TEMPERATURE SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Drain the engine oil. 4. Disconnect the engine oil temperature (EOT) sensor electrical connector. 5. Remove the EOT sensor. Discard the O-ring seal. - To install, tighten to 21 Nm (15 lb-ft). - Install a new O-ring seal. Lubricate the new O-ring seal with clean engine oil prior to installation. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 1991 Oxygen Sensor: Harness Locations View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 1992 View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 1993 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 1994 View 151-8 (Transmission - 6HP26 Automatic Transmission Without Four-Wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 1995 View 151-9 (Transmission - 6HP26 Automatic Transmission With Four-Wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 1996 View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 1997 View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 1998 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 1999 View 151-8 (Transmission - 6HP26 Automatic Transmission Without Four-Wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2000 View 151-9 (Transmission - 6HP26 Automatic Transmission With Four-Wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 C141 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 2003 C142 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 2004 C171 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 2005 C172 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2006 Oxygen Sensor: Description and Operation HEATED OXYGEN SENSOR (HO2S) Heated Oxygen Sensor (HO2S) The HO2S detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to a temperature of 800°C (1,472°F). At approximately 300°C (572°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater. The PCM turns the heater on by providing the ground when the correct conditions occur. The heater allows the engine to enter closed loop operation sooner. The use of this heater requires the HO2S heater control to be duty cycled, to prevent damage to the heater. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) HEATED OXYGEN SENSOR (HO2S) Exploded View Special Tool(s) Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the heated oxygen sensor (HO2S) electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 2009 3. Using the special tool, remove the HO2S. - To install, tighten to 46 Nm (34 lb-ft). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 2010 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor CATALYST MONITOR SENSOR Exploded View Special Tool(s) Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the catalyst monitor sensor electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 2011 3. Using the special tool, remove the catalyst monitor sensor. - To install, tighten to 46 Nm (34 lb-ft). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch POWER STEERING PRESSURE (PSP) SWITCH Typical Power Steering Pressure (PSP) Switch The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch > Page 2016 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor POWER STEERING PRESSURE (PSP) SENSOR Typical Power Steering Pressure (PSP) Sensor The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM changes as the hydraulic pressure changes. The PCM uses the input signal from the PSP sensor to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP sensor signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback Exhaust Gas Recirculation (EGR) (DPFE) Sensor Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback Exhaust Gas Recirculation (EGR) (DPFE) Sensor DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) (DPFE) SENSOR DPFE Sensor The DPFE sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through 2 hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the DPFE sensor housing for identification (note that the HI signal uses a larger diameter hose). The DPFE sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the powertrain control module (PCM) as EGR flow rate feedback. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback Exhaust Gas Recirculation (EGR) (DPFE) Sensor > Page 2021 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback Exhaust Gas Recirculation (EGR) (DPFE) Sensor - Tube Mounted DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) (DPFE) SENSOR - TUBE MOUNTED DPFE Sensor - Tube Mounted The tube mounted DPFE sensor is identical in operation as the larger plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2025 C189 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Electronic Throttle Body (ETB) Position Sensor Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR The ETB position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB position signals are required for increased monitoring. The first ETB position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). During normal operation the negative slope ETB position sensor signal (TP1) is used by the control strategy as the indication of throttle position. The 2 ETB position sensor signals make sure the PCM receives a correct input even if 1 signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Electronic Throttle Body (ETB) Position Sensor > Page 2028 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor THROTTLE POSITION (TP) SENSOR Typical TP Sensor The TP sensor is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a 3-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page 2029 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Removal 1. Disconnect the battery ground cable. 2. Remove the air cleaner inlet pipe and the air cleaner assembly. 3. Disconnect the throttle position (TP) sensor electrical connector. 4. CAUTION: Failure to remove the TP sensor screws in the following manner will result in damage to the screws. First loosen the screws 1-2 full turns using a hand tool and then use a suitable high speed driver to complete the removal. Remove and discard the 2 screws and the TP sensor. Installation 1. CAUTION: - Do not reuse the TP sensor and screws. A new TP sensor and screws must be installed. - Do not use a high speed driver to install the new screws or damage to the TP sensor can occur. NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor is aligned with the radial locator hole on the throttle body. Position the new TP sensor and install the 2 new screws. Tighten to 3 Nm (27 lb-in). 2. Connect the TP sensor electrical connector. 3. Install the air cleaner and air cleaner inlet pipe. 4. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2033 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2036 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2037 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2038 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2039 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2040 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2041 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2042 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2043 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2044 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2045 Transmission Position Switch/Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2046 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2047 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2048 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2049 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2050 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2051 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2052 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2053 C167 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2054 Transmission Position Switch/Sensor: Adjustments 4R70E/4R75E Transmission Range (TR) Sensor Adjustment Special Tools 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual lever shift control cable. 3. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control lever nut. 2 Remove the manual control lever. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2055 4. Loosen the digital transmission range (TR) sensor bolts. 5. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 6. CAUTION: Tightening one bolt before tightening the other may cause the sensor to bind or become damaged. Using the special tool, align the digital TR sensor and tighten the bolts in an alternating sequence. ^ Tighten to 9 Nm (80 inch lbs.). 7. Install the manual control lever. ^ Position the manual control lever. 2 Install a new manual lever shaft outer nut. ^ Tighten to 33 Nm (24 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2056 8. With the manual lever in overdrive connect the shift lever control cable. 9. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2057 Transmission Position Switch/Sensor: Service and Repair 4R70E/4R75E Automatic Transmission Digital Transmission Range (TR) Sensor Special Tools Removal NOTE: Manual shift lever must be in the NEUTRAL position. 1. With the vehicle in NEUTRAL, position it on a hoist. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2058 2. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual control lever shift control cable. 3. Disconnect the digital TR electrical connector. 4. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control nut. 2 Remove the manual control lever. 5. Remove the digital TR sensor bolts and the digital TR sensor. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2059 1. Install the digital TR sensor and loosely install the bolts. 2. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 3. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. Tighten the digital TR sensor bolts. ^ Tighten to 9 Nm (80 inch lbs.). 4. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual control lever nut. ^ Tighten to 33 Nm (24 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2060 5. Connect the digital TR sensor electrical connector. 6. Connect the shift cable end to the manual lever with the lever in the (D) position. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Output Shaft Speed (OSS) Sensor Vehicle Speed Sensor: Description and Operation Output Shaft Speed (OSS) Sensor OUTPUT SHAFT SPEED (OSS) SENSOR The OSS sensor provides the PCM with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Output Shaft Speed (OSS) Sensor > Page 2065 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) VEHICLE SPEED SENSOR (VSS) Typical Vehicle Speed Sensor (VSS) The VSS is a variable reluctance or HALL-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling, and torque converter clutch scheduling. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback Exhaust Gas Recirculation (EGR) (DPFE) Sensor Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback Exhaust Gas Recirculation (EGR) (DPFE) Sensor DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) (DPFE) SENSOR DPFE Sensor The DPFE sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through 2 hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the DPFE sensor housing for identification (note that the HI signal uses a larger diameter hose). The DPFE sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the powertrain control module (PCM) as EGR flow rate feedback. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback Exhaust Gas Recirculation (EGR) (DPFE) Sensor > Page 2071 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback Exhaust Gas Recirculation (EGR) (DPFE) Sensor - Tube Mounted DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) (DPFE) SENSOR - TUBE MOUNTED DPFE Sensor - Tube Mounted The tube mounted DPFE sensor is identical in operation as the larger plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2076 C2040 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2077 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The APP sensor is an input to the powertrain control module (PCM) and is used to determine the torque demand. There are 3 pedal position signals in the sensor. Signal 1, APPS1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, APPS2 and APPS3, both have a positive slope (increasing angle, increasing voltage). During normal operation APPS1 is used as the indication of pedal position by the strategy. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. There are 2 reference voltage circuits and 2 signal return circuits for the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2081 C1454 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2082 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW (MAF) SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT Sensor Wire Where Applicable) Terminals Typical Mass Air Flow (MAF) Sensor Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2083 Typical Drop-in Mass Air Flow (MAF) Sensor The MAF sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above the ambient temperature as measured by a constant cold wire. If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the mass air flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. Most MAF sensors have integrated bypass technology (IBT) with an integrated intake air temperature (IAT) sensor. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2084 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the mass air flow (MAF) sensor electrical connector. 3. Remove the 2 bolts and the MAF sensor. - To install, tighten to 7 Nm (62 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Fuel Rail Pressure Sensor View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Fuel Rail Pressure Sensor > Page 2089 View 151-36 (Chassis, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Fuel Rail Pressure/Temperature Sensor C1475 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Fuel Rail Pressure/Temperature Sensor > Page 2092 C435 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation > Fuel Rail Pressure (FRP) Sensor Fuel Pressure Sensor/Switch: Description and Operation Fuel Rail Pressure (FRP) Sensor FUEL RAIL PRESSURE (FRP) SENSOR Fuel Rail Pressure (FRP) Sensor The FRP sensor is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and the resistance decreases as the pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation > Fuel Rail Pressure (FRP) Sensor > Page 2095 Fuel Pressure Sensor/Switch: Description and Operation Fuel Rail Pressure Temperature (FRPT) Sensor FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR Typical Fuel Rail Pressure Temperature (FRPT) Sensor The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to determine the pressure difference between the fuel rail and the intake manifold. The relationship between fuel pressure and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. Both pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation > Page 2096 Fuel Pressure Sensor/Switch: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE (FRPT) SENSOR Removal and Installation WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before 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. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel rail pressure and temperature (FRPT) sensor electrical and vacuum connectors. 4. Remove the 2 bolts and the FRPT sensor and discard the O-ring seal. - To install, tighten to 10 Nm (89 lb-in). - Install a new O-ring seal. - Lubricate the new O-ring seal prior to installation. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 2100 C1475 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation > Fuel Rail Pressure Temperature (FRPT) Sensor Fuel Temperature Sensor: Description and Operation Fuel Rail Pressure Temperature (FRPT) Sensor FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR Typical Fuel Rail Pressure Temperature (FRPT) Sensor The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to determine the pressure difference between the fuel rail and the intake manifold. The relationship between fuel pressure and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. Both pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation > Fuel Rail Pressure Temperature (FRPT) Sensor > Page 2103 Fuel Temperature Sensor: Description and Operation Fuel Rail Temperature (FRT) Sensor FUEL RAIL TEMPERATURE (FRT) SENSOR Fuel Rail Temperature (FRT) Sensor The FRT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRT sensor measures the temperature of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation > Page 2104 Fuel Temperature Sensor: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE (FRPT) SENSOR Removal and Installation WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before 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. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel rail pressure and temperature (FRPT) sensor electrical and vacuum connectors. 4. Remove the 2 bolts and the FRPT sensor and discard the O-ring seal. - To install, tighten to 10 Nm (89 lb-in). - Install a new O-ring seal. - Lubricate the new O-ring seal prior to installation. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations View 151-19 (Left Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 2108 C4168 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 2109 Inertia Fuel Shutoff Switch: Description and Operation INERTIA FUEL SHUTOFF (IFS) SWITCH Typical Inertia Fuel Shutoff (IFS) Switch The IFS switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shutoff the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner's Literature for the location of the IFS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 2110 Inertia Fuel Shutoff Switch: Service and Repair INERTIA FUEL SHUTOFF (IFS) SWITCH Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the LH rear interior quarter trim panel. 3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Remove the 2 bolts and the IFS switch. - To install, tighten to 10 Nm (89 lb-in). 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2114 C189 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Electronic Throttle Body (ETB) Position Sensor Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR The ETB position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB position signals are required for increased monitoring. The first ETB position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). During normal operation the negative slope ETB position sensor signal (TP1) is used by the control strategy as the indication of throttle position. The 2 ETB position sensor signals make sure the PCM receives a correct input even if 1 signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Electronic Throttle Body (ETB) Position Sensor > Page 2117 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor THROTTLE POSITION (TP) SENSOR Typical TP Sensor The TP sensor is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a 3-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 2118 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Removal 1. Disconnect the battery ground cable. 2. Remove the air cleaner inlet pipe and the air cleaner assembly. 3. Disconnect the throttle position (TP) sensor electrical connector. 4. CAUTION: Failure to remove the TP sensor screws in the following manner will result in damage to the screws. First loosen the screws 1-2 full turns using a hand tool and then use a suitable high speed driver to complete the removal. Remove and discard the 2 screws and the TP sensor. Installation 1. CAUTION: - Do not reuse the TP sensor and screws. A new TP sensor and screws must be installed. - Do not use a high speed driver to install the new screws or damage to the TP sensor can occur. NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor is aligned with the radial locator hole on the throttle body. Position the new TP sensor and install the 2 new screws. Tighten to 3 Nm (27 lb-in). 2. Connect the TP sensor electrical connector. 3. Install the air cleaner and air cleaner inlet pipe. 4. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1 C1366 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1 > Page 2125 C1367 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2126 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR Typical Synchronizer Hall-Effect CMP Sensor Typical Variable Reluctance CMP Sensor The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston No. 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to select the correct ignition coil to fire. Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor and the 2-pin connector variable reluctance type sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2127 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the camshaft position (CMP) sensor electrical connector. 3. Remove the bolt and the CMP sensor. Discard the O-ring seal. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2131 C101 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2132 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Typical Crankshaft Position (CKP) Sensor The CKP sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L 10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2133 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the accessory drive belt. 4. Disconnect the A/C compressor electrical connector. 5. Remove the 3 bolts and position the A/C compressor aside. - To install, tighten to 25 Nm (18 lb-ft). 6. Disconnect the crankshaft position (CKP) sensor electrical connector. 7. Remove the bolt and the CKP sensor. Discard the O-ring seal. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the new O-ring seal with clean engine oil prior to installation. 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Locations View 151-14 (Steering Column) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions Ignition Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2139 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2140 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2141 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2142 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2143 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2144 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2145 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2146 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2147 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2148 Ignition Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2149 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2150 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2151 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2152 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2153 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2154 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2155 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2156 C250 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Page 2157 Ignition Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Page 2158 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Page 2159 Ignition Switch: Service and Repair Ignition Switch Ignition Switch Removal and Installation 1. Remove the steering wheel. 2. NOTE: Lower tilt release handle to access second screw. Remove the lower steering column shroud. ^ Remove the screws. 3. NOTE: The screw is located behind the multi-function switch. Remove the screw and the upper steering column shroud. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Page 2160 4. Remove the bolt, push the release and position the multi-function switch aside. 5. Disconnect the ignition switch electrical connector. 6. Remove the ignition switch. 7. To install, reverse the removal procedure. ^ Make sure that the spring located under the ignition switch is positioned on the steering column lock rod. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 C109 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 2166 C108 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 2167 Knock Sensor: Description and Operation KNOCK SENSOR (KS) Two Types Of Knock Sensor (KS) The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 2168 Knock Sensor: Service and Repair KNOCK SENSOR (KS) Removal and Installation 1. Remove the intake manifold. 2. Disconnect the knock sensor (KS) electrical connectors. 3. Remove the 2 bolts and the 2 knock sensors. - To install, tighten to 20 Nm (15 lb-ft). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor View 151-1 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 2174 View 151-19 (Left Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 2175 View 151-21 (Right Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 2176 View 151-28 (Driver Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 2177 View 151-29 (Passenger Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Forward Crash Sensor C177 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Forward Crash Sensor > Page 2180 C539 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Forward Crash Sensor > Page 2181 C631 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Forward Crash Sensor > Page 2182 C9004 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Forward Crash Sensor > Page 2183 C9005 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Page 2184 Impact Sensor: Description and Operation SENSORS WARNING: - The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the RCM must be replaced whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. - Vehicle sensor orientation is critical for correct 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 correctly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. For these vehicles, the SRS uses up to 8 sensors. Within the RCM there can be up to 3 safing sensors which are not separately serviced. The RCM will always have at least 1 safing sensor for front impact. Two more safing sensors are used if the vehicle is equipped with safety canopy modules. The RCM is mounted to the center tunnel beneath the console or bench seat. All vehicles will have a front impact severity sensor that is located in the front-center of the vehicle, mounted near the bottom of the hood latch support bracket. If the vehicle is equipped with safety canopy modules, there are 4 additional side impact sensors external to the RCM. One front row side impact sensor is located behind each of the front door interior trim panels. One second row side impact sensor is located at the base of each C-pillar. Mounting orientation is critical for correct operation of all impact and rollover sensors. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor Impact Sensor: Service and Repair Front Impact Severity Sensor FRONT IMPACT SEVERITY SENSOR Removal and Installation WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - Front bumper removed for clarity. 1. Depower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 2187 2. NOTE: The front impact severity sensor is mounted on the bottom of the hood latch support bracket. Remove the pin-type retainers and lower the front lower splash shield to access the front impact severity sensor. 3. WARNING: The tightening torque of the air bag front impact severity sensor retaining nut is critical for correct system operation. CAUTION: If the hood latch support bracket or weld stud are damaged in any way that would affect the way the front impact severity sensor mounts to its original manufactured position, a new hood latch support bracket must be installed. NOTE: Note the position of the front impact severity sensor locator tabs to the hood latch support bracket alignment holes for installation. - Make sure the hood latch support bracket and front impact severity sensor mating surfaces are clean and debris free. Remove the front impact severity sensor nut. To install, tighten to 12 Nm (9 lb-ft) 4. Disconnect the electrical connector and remove the front impact severity sensor. 5. To install, reverse the removal procedure. 6. Repower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 2188 Impact Sensor: Service and Repair Side Impact Sensor - C-Pillar SIDE IMPACT SENSOR - C-PILLAR 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. - Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and correctly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To reduce the risk of personal injury, do not use any memory saver devices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 2189 NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. - Driver side shown, passenger side similar. 1. Depower the system. 2. Lift to release and remove the rear door scuff plate. 3. Remove the safety belt retractor anchor bolt. 4. Pull out at the front of the rear quarter trim panel, releasing the retaining clips, allowing access to the side impact sensor. 5. Remove the side impact sensor bolt. 6. Disconnect the side impact sensor electrical connector and remove the sensor and bracket. Installation 1. Make sure the second row side impact sensor tabs are aligned to the bracket. 2. Position the side impact sensor and bracket locator pin to the opening in the quarter panel sheet metal and install the bolt. - To install, tighten to 12 Nm (9 lb-ft). 3. Connect the side impact sensor electrical connector. 4. Align the rear quarter trim panel and push in, seating the retaining clips. 5. NOTE: Make sure the safety belt webbing is not twisted prior to installation. Install the safety belt retractor anchor bolt. To install, tighten to 40 Nm (30 lb-ft). - Verify the safety belt retractor operates without excessive effort or binding. 6. Install the rear door scuff plate. 7. Repower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 2190 Impact Sensor: Service and Repair Side Impact Sensor - Front Door SIDE IMPACT SENSOR - FRONT DOOR Removal and Installation WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Vehicle sensor orientation is critical for 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 reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - Driver side shown, passenger side similar. 1. Depower the system. 2. Remove the front interior door trim panel on the side with the affected side impact sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 2191 3. Separate the weathershield enough to access the side impact sensor. 4. Disconnect the side impact sensor electrical connector. 5. WARNING: The tightening torque of the side impact sensor retaining bolt is critical for correct system operation. CAUTION: The ground wire must be placed between the bolt head and the sensor. Never position the ground wire between the J-clip retaining nut and the sensor. - Always replace the J-clip retaining nut whenever installing a side impact sensor. NOTE: Make sure the side impact sensor mating surfaces are clean and free of foreign material. - Note the position of the side impact sensor locating tabs for installation. Remove the bolt and the side impact sensor. To install, tighten to 12 Nm (9 lb-ft). 6. To install, reverse the removal procedure. 7. Repower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger View 151-17 (RH A-Pillar) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger > Page 2196 View 151-26 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver C3065 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver > Page 2199 C3066 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Page 2200 Seat Belt Buckle Switch: Description and Operation SAFETY BELT BUCKLE SWITCHES As part of the supplemental restraint system (SRS), the driver and front outboard passenger safety belt buckles are equipped with safety belt buckle switches. The safety belt buckle switches indicate to the restraints control module (RCM) whether the safety belts are connected or disconnected. The RCM uses this information in determining the deployment rate of the dual-stage driver and passenger air bag modules. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations View 151-26 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 2204 C356 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 2205 Seat Sensor/Switch: Description and Operation SEAT TRACK POSITION SENSOR The seat track position sensor is mounted to a bracket attached to the inboard side of the seat track. The seat track position sensor informs the restraints control module (RCM) of the driver seat position. The RCM uses this information in determining the deployment rate of the dual-stage driver air bag module. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Locations View 151-14 (Steering Column) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions Ignition Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2212 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2213 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2214 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2215 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2216 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2217 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2218 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2219 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2220 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2221 Ignition Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2222 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2223 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2224 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2225 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2226 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2227 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2228 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2229 C250 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Page 2230 Ignition Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Page 2231 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Page 2232 Ignition Switch: Service and Repair Ignition Switch Ignition Switch Removal and Installation 1. Remove the steering wheel. 2. NOTE: Lower tilt release handle to access second screw. Remove the lower steering column shroud. ^ Remove the screws. 3. NOTE: The screw is located behind the multi-function switch. Remove the screw and the upper steering column shroud. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Page 2233 4. Remove the bolt, push the release and position the multi-function switch aside. 5. Disconnect the ignition switch electrical connector. 6. Remove the ignition switch. 7. To install, reverse the removal procedure. ^ Make sure that the spring located under the ignition switch is positioned on the steering column lock rod. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 2237 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 2238 C167 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch POWER STEERING PRESSURE (PSP) SWITCH Typical Power Steering Pressure (PSP) Switch The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch > Page 2245 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor POWER STEERING PRESSURE (PSP) SENSOR Typical Power Steering Pressure (PSP) Sensor The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM changes as the hydraulic pressure changes. The PCM uses the input signal from the PSP sensor to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP sensor signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations View 151-14 (Steering Column) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 2249 C226 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins > Customer Interest for Ride Height Sensor: > 06-15-10 > Aug > 06 > Suspension - Air Suspension Height Sensor Linkage Loose Ride Height Sensor: Customer Interest Suspension - Air Suspension Height Sensor Linkage Loose TSB 06-15-10 08/07/06 AIR SUSPENSION PERFORMANCE - HEIGHT SENSOR LINKAGE ARM DISENGAGING FORD: 2003-2006 Expedition LINCOLN: 2003-2006 Navigator ISSUE Some 2003-2006 Expedition and Navigator vehicles equipped with an air suspension may exhibit an air suspension height sensor linkage arm disengaging from the suspension ball stud or height sensor rotating arm. This concern typically occurs with the rear sensor (Figure 1) but may occur with the front sensors as well. If this occurs, the symptom will typically be the vehicle leaning to one side, the vehicle sitting too low/high, a harsh ride, and/or an inoperative air suspension. In addition, this concern may result in diagnostic trouble code (DTC) C1725 (air suspension front pneumatic failure) or C1726 (air suspension rear pneumatic failure). ACTION When a linkage arm becomes disengaged, do not re-attach the arm and do not replace the sensor unless broken. Instead, install a revised linkage arm on all three (3) sensor assemblies, even if they have not detached from the ball stud. Refer to the following Service Procedure. SERVICE PROCEDURE Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins > Customer Interest for Ride Height Sensor: > 06-15-10 > Aug > 06 > Suspension - Air Suspension Height Sensor Linkage Loose > Page 2259 NOTE LINKAGE ARMS USED AS ORIGINAL EQUIPMENT ARE SHOWN IN FIGURE 2. REVISED LINKAGE ARMS (FIGURE 3) HAVE A NEW DESIGN THAT MAKES IT MORE DIFFICULT TO DISENGAGE FROM THE BALL STUDS. NOTE IF THE SENSOR ASSEMBLY NEEDS TO BE REPLACED FOR ANY DAMAGE/FAILURE OTHER THAN THE ONE DESCRIBED IN THIS TSB, THE REPLACEMENT ASSEMBLY IS SUPPLIED WITH A NEW STYLE LINKAGE ARM, SO THERE IS NO NEED TO ORDER ADDITIONAL LINKAGES FOR THE SERVICE REPAIR. 1. Replace linkage arms on all three (3) sensor assemblies following Workshop Manual (WSM), Section 204-05. 2. Discard the old linkage arms. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061510A 2003-2006 0.4 Hr. Expedition/Navigator: Replace The Three Linkage Arms, Includes Time To Check Diagnostic Trouble Codes (Do Not Use With 5300A, 5300A7, 5300A8) DEALER CODING CONDITION BASIC PART NO. CODE 5A967 07 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ride Height Sensor: > 06-15-10 > Aug > 06 > Suspension - Air Suspension Height Sensor Linkage Loose Ride Height Sensor: All Technical Service Bulletins Suspension - Air Suspension Height Sensor Linkage Loose TSB 06-15-10 08/07/06 AIR SUSPENSION PERFORMANCE - HEIGHT SENSOR LINKAGE ARM DISENGAGING FORD: 2003-2006 Expedition LINCOLN: 2003-2006 Navigator ISSUE Some 2003-2006 Expedition and Navigator vehicles equipped with an air suspension may exhibit an air suspension height sensor linkage arm disengaging from the suspension ball stud or height sensor rotating arm. This concern typically occurs with the rear sensor (Figure 1) but may occur with the front sensors as well. If this occurs, the symptom will typically be the vehicle leaning to one side, the vehicle sitting too low/high, a harsh ride, and/or an inoperative air suspension. In addition, this concern may result in diagnostic trouble code (DTC) C1725 (air suspension front pneumatic failure) or C1726 (air suspension rear pneumatic failure). ACTION When a linkage arm becomes disengaged, do not re-attach the arm and do not replace the sensor unless broken. Instead, install a revised linkage arm on all three (3) sensor assemblies, even if they have not detached from the ball stud. Refer to the following Service Procedure. SERVICE PROCEDURE Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ride Height Sensor: > 06-15-10 > Aug > 06 > Suspension - Air Suspension Height Sensor Linkage Loose > Page 2265 NOTE LINKAGE ARMS USED AS ORIGINAL EQUIPMENT ARE SHOWN IN FIGURE 2. REVISED LINKAGE ARMS (FIGURE 3) HAVE A NEW DESIGN THAT MAKES IT MORE DIFFICULT TO DISENGAGE FROM THE BALL STUDS. NOTE IF THE SENSOR ASSEMBLY NEEDS TO BE REPLACED FOR ANY DAMAGE/FAILURE OTHER THAN THE ONE DESCRIBED IN THIS TSB, THE REPLACEMENT ASSEMBLY IS SUPPLIED WITH A NEW STYLE LINKAGE ARM, SO THERE IS NO NEED TO ORDER ADDITIONAL LINKAGES FOR THE SERVICE REPAIR. 1. Replace linkage arms on all three (3) sensor assemblies following Workshop Manual (WSM), Section 204-05. 2. Discard the old linkage arms. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061510A 2003-2006 0.4 Hr. Expedition/Navigator: Replace The Three Linkage Arms, Includes Time To Check Diagnostic Trouble Codes (Do Not Use With 5300A, 5300A7, 5300A8) DEALER CODING CONDITION BASIC PART NO. CODE 5A967 07 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins > Page 2266 Ride Height Sensor: Service and Repair Suspension Height Sensor Front Height Sensor Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins > Page 2267 Rear Height Sensor Removal and Installation 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 LH quarter trim panel. 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. All sensors 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the sensor arm from the vehicle. Front sensor 3. Remove and discard the 2 sensor nuts. ^ To install, tighten to 30 Nm (22 ft. lbs.). Rear sensor 4. Remove and discard the sensor nuts and bolts. ^ To install, tighten to 15 Nm (13 ft. lbs.). All sensors 5. Disconnect the sensor electrical connector. 6. NOTE: The RH and LH height sensors cannot be used on opposite sides of the vehicle. To install, reverse the removal procedure. 7. Calibrate the height sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations View 151-14 (Steering Column) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 2271 C226 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Locations View 151-19 (Left Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Locations > Page 2275 C4169 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection Tire Pressure Sensor: Testing and Inspection Sensor Training (Reset Procedure) NOTE: The tire pressure monitoring system is not affected by wheel and tire rotation. NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area without radio frequency (RF) noise. RF noise is generated by electrical motor and appliance operation, cellular telephones and remote transmitters, power inverters and portable entertainment equipment. 1. Turn the ignition switch to the OFF position. 2. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. Do not wait more than 1 minute between each key cycle. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. Do not wait more than 1 minute between each key cycle. 6. The horn will sound once and the TPMS indicator will flash if train mode has been entered successfully. If equipped, the message center displays "TRAIN LF TIRE", place the special tool on the valve stem of the LF tire pressure sensor. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the TPMS module. 7. Within 2 minutes after the horn sounds, place the special tool on the valve stem of the RF tire pressure sensor. NOTE: If the VSM (TPMS module integral to VSM) does not recognize any 1 of the 4 tire pressure sensors during the tire training procedure, the horn will sound twice and the message center (if equipped) will display "TIRE NOT TRAINED REPEAT" and the procedure must be repeated. 8. Repeat Step 7 for the RR and LR tires. When the tire training procedure is complete, the horn will sound once and the message center (if equipped) will display "TIRE TRAINING MODE COMPLETE". Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 2280 Tire Pressure Sensor: Service and Repair Tire Pressure Sensor Special Tools CAUTION: Use only special tool 204-354 anytime tire pressures are measured to be sure that accurate values are obtained. CAUTION: Place the air chuck straight on the valve stem to inflate the tire. Do not cock the air chuck during the inflation cycle. Doing so can damage the valve stem and cause air leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 2281 CAUTION: Ford recommends using a round head air chuck on tire pressure sensors; it is not recommended to use air chucks with long shanks. Doing so can cause tire pressure sensor valve stem damage and loss of tire pressure. Removal NOTE: The vehicle is equipped with a light blue-colored tire pressure sensor. When installing new components, use only this tire pressure sensor. The tire pressure monitoring system (TPM's) will not operate correctly if black-colored tire pressure sensors are installed. 1. Remove the wheel and tire assembly. 2. CAUTION: Do not remove the valve stem core to relieve the tire pressure. CAUTION: If the valve stem core has been removed from the valve stem, reinstall the original valve stem core. If the original valve stem core is damaged, a nickel-plated core must be installed. Failure to use a nickel-plated core will result in corrosion and the possible loss of tire pressure. NOTE: Release the tire pressure by removing the sensor valve stem nut. With the valve stem at the 6 o'clock position, remove the sensor valve stem nut and push the sensor by hand into the tire (with the cap on). 3. Using a suitable tire machine, separate both beads of the tire from the wheel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 2282 4. CAUTION: Care should be taken not to damage the tire pressure sensor while separating the outside bead of tire from the wheel. Place the wheel and tire on the turntable of the tire machine, index-mark the valve stem and wheel weight positions, lubricate the bead of the tire and dismount the outside bead of the tire from the wheel. 5. Remove the tire pressure sensor from the tire. 6. Remove and discard the grommet from the tire pressure sensor. Installation NOTE: The vehicle is equipped with a light blue-colored tire pressure sensor. When installing new components, use only this tire pressure sensor. The TPM's will not operate correctly if black-colored tire pressure sensors are installed. 1. NOTE: Install a new sensor grommet or an air leak can occur. Install a new grommet on the tire pressure sensor. 2. NOTE: Do not allow the tire to rotate relative to the rim while mounting the tire. Lubricate and mount the outside and inside bead of the tire to the rim. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 2283 3. CAUTION: Overtightening the tire pressure sensor valve stem nut can damage the tire pressure sensor, undertightening can cause air leaks. NOTE: Sensor position is critical for correct sensor operation. The "flat" side of the sensor must be facing the wheel and the "slanted" side of the sensor must be facing away from the wheel. When properly installed, there will be a very small gap between the sensor and the wheel. NOTE: Tightening the nut to 5 Nm (44 inch lbs.) equals approximately 2 clockwise turns after the nut has been tightened by hand. Push the side wall of the tire and install the tire pressure sensor. Tighten the nut to 5 Nm (44 inch lbs.). 4. CAUTION: Use only special tool 204-354 anytime tire pressures are measured to be sure that accurate values are obtained. CAUTION: Place the air chuck straight on the valve stem to inflate the tire. Do not cock the air chuck during the inflation cycle. Doing so can damage the valve stem and cause air leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 2284 CAUTION: Ford recommends using a round head air chuck on tire pressure sensors; it is not recommended to use air chucks with long shanks. Doing so can cause tire pressure sensor valve stem damage and loss of tire pressure. CAUTION: Use only OEM valve caps (aluminum or plastic valve caps) with the tire pressure sensors. Do not use brass-threaded valve caps with the tire pressure sensors. Inflate the tire to the pressure specified on the safety certification sticker located on the driver or door pillar. 5. Install the wheel and tire assembly. 6. Train the tire pressure sensors. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions Brake Switch - TCC: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 2291 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 2292 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 2293 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 2294 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 2295 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 2296 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 2297 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 2298 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 2299 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 2300 Brake Switch - TCC: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 2301 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 2302 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 2303 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 2304 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 2305 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 2306 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 2307 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Page 2308 Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - BPP switch is hardwired to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - BPP switch is hardwired to the Anti-Lock Brake System (ABS) Module, Lighting Control Module (LCM), or Rear Electronic Module (REM), the BPP signal is then broadcast over the network to be received by the PCM. - BPP switch is hardwired to the anti-lock brake system (ABS) traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations View 151-14 (Steering Column) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Overdrive Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2314 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2315 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2316 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2317 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2318 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2319 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2320 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2321 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2322 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2323 Overdrive Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2324 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2325 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2326 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2327 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2328 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2329 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2330 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2331 C2135 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor/Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2336 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2337 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2338 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2339 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2340 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2341 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2342 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2343 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2344 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2345 Throttle Position Sensor/Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2346 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2347 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2348 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2349 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2350 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2351 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2352 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Mode Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2357 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2358 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2359 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2360 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2361 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2362 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2363 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2364 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2365 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2366 Transmission Mode Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2367 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2368 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2369 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2370 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2371 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2372 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2373 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 2374 Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH (TCS) Typical Transmission Control Switch (TCS) Typical Transmission Control Switch (TCS) The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature, the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage overdrive. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2378 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2381 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2382 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2383 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2384 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2385 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2386 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2387 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2388 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2389 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2390 Transmission Position Switch/Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2391 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2392 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2393 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2394 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2395 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2396 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2397 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2398 C167 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2399 Transmission Position Switch/Sensor: Adjustments 4R70E/4R75E Transmission Range (TR) Sensor Adjustment Special Tools 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual lever shift control cable. 3. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control lever nut. 2 Remove the manual control lever. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2400 4. Loosen the digital transmission range (TR) sensor bolts. 5. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 6. CAUTION: Tightening one bolt before tightening the other may cause the sensor to bind or become damaged. Using the special tool, align the digital TR sensor and tighten the bolts in an alternating sequence. ^ Tighten to 9 Nm (80 inch lbs.). 7. Install the manual control lever. ^ Position the manual control lever. 2 Install a new manual lever shaft outer nut. ^ Tighten to 33 Nm (24 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2401 8. With the manual lever in overdrive connect the shift lever control cable. 9. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2402 Transmission Position Switch/Sensor: Service and Repair 4R70E/4R75E Automatic Transmission Digital Transmission Range (TR) Sensor Special Tools Removal NOTE: Manual shift lever must be in the NEUTRAL position. 1. With the vehicle in NEUTRAL, position it on a hoist. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2403 2. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual control lever shift control cable. 3. Disconnect the digital TR electrical connector. 4. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control nut. 2 Remove the manual control lever. 5. Remove the digital TR sensor bolts and the digital TR sensor. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2404 1. Install the digital TR sensor and loosely install the bolts. 2. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 3. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. Tighten the digital TR sensor bolts. ^ Tighten to 9 Nm (80 inch lbs.). 4. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual control lever nut. ^ Tighten to 33 Nm (24 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2405 5. Connect the digital TR sensor electrical connector. 6. Connect the shift cable end to the manual lever with the lever in the (D) position. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Turbine Shaft Speed (TSS) Sensor > Page 2410 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Turbine Shaft Speed (TSS) Sensor > Page 2411 Transmission Speed Sensor: Locations Output Shaft Speed (OSS) Sensor View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Turbine Shaft Speed (TSS) Sensor > Page 2412 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Speed Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2415 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2416 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2417 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2418 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2419 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2420 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2421 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2422 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2423 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2424 Transmission Speed Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2425 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2426 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2427 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2428 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2429 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2430 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2431 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2432 Transmission Speed Sensor: Connector Views C193 C143 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 2433 Transmission Speed Sensor: Service and Repair 4R70E/4R75E Automatic Transmission Speed Sensors Speed Sensors NOTE: Only remove the affected sensor. Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist, OSS sensor 2. Disconnect the output shaft speed (OSS) sensor electrical connector. 3. Remove the OSS sensor bolt. 4. Remove the OSS sensor. TSS sensor 5. Disconnect the turbine shaft speed (TSS) sensor electrical connector. 6. Remove the TSS sensor bolt. 7. Remove the TSS sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 2434 Installation TSS sensor 1. Lubricate the O-ring seal and install the TSS sensor. 2. Install the TSS sensor bolt. ^ Tighten to 11 Nm (8 ft. lbs.). 3. Connect the TSS sensor electrical connector. OSS sensor 4. Lubricate the O-ring seal and install the OSS sensor. 5. Install the OSS sensor bolt. ^ Tighten to 12 Nm (9 ft. lbs.). 6. Connect the OSS sensor electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations View 151-12 (Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 2439 C284 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch View 151-28 (Driver Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 2445 View 151-29 (Passenger Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 2446 View 151-30 (Left Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 2447 View 151-31 (Right Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 2448 View 151-23 (Roof) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch Power Window Switch: Diagrams Master Window Adjust Switch C504a C504b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 2451 C3193a C3193b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 2452 Power Window Switch: Diagrams Window Adjust Switch, Left Rear C701 C717 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 2453 Power Window Switch: Diagrams Window Adjust Switch, Right Rear C801 C819 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 2454 C624 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 2455 Power Window Switch: Diagrams Power Quarter Window Switch C998 C999 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch Power Window Switch: Testing and Inspection Master Window Adjust Switch Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 2458 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 2459 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 2460 Power Window Switch: Testing and Inspection Power Quarter Window Switch Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 2461 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 2462 Power Window Switch: Testing and Inspection Power Window Switch, RH Side Front Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 2463 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 2464 Power Window Switch: Testing and Inspection Window Adjust Switch Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 2465 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 2466 Power Window Switch: Service and Repair WINDOW CONTROL SWITCH Removal and Installation Navigator front 1. Lift up on the center console armrest. 2. Remove the center console window control switch panel. - Remove the pin-type retainer. 3. Disconnect the electrical connectors and remove the window control switch. - Release the locking tabs. Expedition front and Expedition passenger rear NOTE: Driver side Expedition shown, all others similar. 4. Remove the window control switch panel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 2467 5. Disconnect the electrical connector(s) and remove the window control switch. - Release the locking tabs. Navigator passenger rear 6. Remove the rear door trim panel. 7. Remove the window control switch from the door trim panel. All vehicles 8. To install, reverse removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 2472 C138 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations View 151-14 (Steering Column) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 2476 Windshield Washer Switch: Diagrams C202a C202b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 2477 C202c Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 2478 Windshield Washer Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 2479 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 2480 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Blade Heater Switch > Component Information > Locations View 151-33 (Climate Control System) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Blade Heater Switch > Component Information > Locations > Page 2484 C2323 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations View 151-14 (Steering Column) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 2488 Wiper Switch: Diagrams C202a C202b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 2489 C202c Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 2490 Wiper Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 2491 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 2492 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications Total Alignment: Specifications Alignment Specifications Total ALIGNMENT SPECIFICATIONS FRONT COIL SPRING SUSPENSION CAMBER LH ........................................................................................................................................................ ...................................................... -0.3° ± 0.75° RH ........................................................................... .................................................................................................................................. -0.3° ± 0.75° Total/Split ............................................................................................................................................. ......................................................... 0° ± 0.75° CASTER LH ........................................................................................................................................................ ......................................................... 5.3° ± 1.0° RH ........................................................................... ...................................................................................................................................... 5.3° ± 1.0° Total/Split ............................................................................................................................................. ......................................................... 0° ± 0.75° TOE @ CURB RIDE HEIGHT LH ........................................................................................................................................................ ...................................................................... --- RH ............................................................................ .................................................................................................................................................. --Total/Split ............................................................................................................................................. .................................................... 0.14° ± 0.20° NOTE: Positive value is toe-in, negative value is toe-out. FRONT AIR SUSPENSION CAMBER LH ........................................................................................................................................................ ............................................ -0.6°/ -0.3° ± 0.75° RH ............................................................................ ....................................................................................................................... -0.6°/ -0.3° ± 0.75° Total/Split ............................................................................................................................................. ......................................................... 0° ± 0.75° CASTER LH ........................................................................................................................................................ ................................................. 5.5°/5.4° ± 1.0° RH ............................................................................ ............................................................................................................................. 5.5°/5.4° ± 1.0° Total/Split ............................................................................................................................................. ......................................................... 0° ± 0.75° TOE @ TRIM RIDE HEIGHT LH ........................................................................................................................................................ ...................................................................... --- RH ............................................................................ .................................................................................................................................................. --Total/Split ............................................................................................................................................. .................................................... 0.14° ± 0.20° NOTE: Positive value is toe-in, negative value is toe-out. REAR COIL SPRING SUSPENSION CAMBER LH ........................................................................................................................................................ ...................................................... -0.9° ± 0.75° RH ........................................................................... .................................................................................................................................. -0.9° ± 0.75° Total/Split ............................................................................................................................................. ......................................................... 0° ± 0.75° TOE @ CURB RIDE HEIGHT LH ........................................................................................................................................................ ...................................................................... --- RH ............................................................................ .................................................................................................................................................. --Total/Split ............................................................................................................................................. .................................................... 0.20° ± 0.20° NOTE: Positive value is toe-in, negative value is toe-out. REAR AIR SUSPENSION CAMBER LH ........................................................................................................................................................ ...................................................... -1.0° ± 0.75° RH ........................................................................... .................................................................................................................................. -1.0° ± 0.75° Total/Split ............................................................................................................................................. ......................................................... 0° ± 0.75° TOE @ TRIM RIDE HEIGHT LH ........................................................................................................................................................ ...................................................................... --- RH ............................................................................ .................................................................................................................................................. --Total/Split ............................................................................................................................................. .................................................... 0.20° ± 0.20° Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications Total > Page 2498 NOTE: Positive value is toe-in, negative value is toe-out. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications Total > Page 2499 Torque Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 2500 Alignment: Description and Operation Wheel Alignment Angles The front caster and camber are adjusted by removing the lower arm front and rear bolts and installing adjuster kits to allow the arm to be adjusted in the frame slots. Front toe is adjusted by the use of the front wheel knuckle tie-rods. The rear camber is adjusted by positioning the upper arm-to-knuckle bolt in the upper arm-to-knuckle slot. The rear toe is adjusted by the use of the rear toe links. Camber Negative and Positive Camber Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or negative and has a direct effect on tire wear. Caster Caster Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed from the side. The caster specifications will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting does not effect tire wear. Toe Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 2501 Positive Toe (Toe In) Negative Toe (Toe Out) The vehicle toe setting: ^ affects tire wear and directional stability. ^ must be checked after adding aftermarket equipment, such as a snowplow. Ride Height NOTE: Air suspension vehicles must be at trim height prior to measuring the vehicle ride height. Front Ride Height Measurement Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 2502 Rear Ride Height Measurement Wheel Track Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 2503 Dogtracking Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can give the illusion of dogtracking. Wander Wander is the tendency of the vehicle to require frequent, random left and right steering wheel corrections to maintain a straight path down a level road. Shimmy Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel resulting from large, side-to-side (lateral) tire/wheel movements. Shimmy is usually experienced near 64 km/h (40 mph), and can begin or be amplified when the tire contacts pot holes or irregularities in the road surface. Nibble Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road surfaces or tire imbalance. This condition is observed by the driver as small rotational oscillations of the steering wheel. Poor Returnability/Sticky Steering Poor returnability and sticky steering is used to describe the poor return of the steering wheel to center after a turn or when the steering correction is completed. Drift/Pull Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep the vehicle going straight. Drift describes what a vehicle with this condition does with hands off the steering wheel. ^ A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead path and require constant steering input in the opposite direction to counteract the effect ^ Drift/Pull may be induced by conditions external to the vehicle (such as wind or road camber). Poor Groove Feel Poor groove feel is, characterized by little or no buildup of turning effort felt in the steering wheel as the wheel is rocked slowly left and right within very small turns around center or straight-ahead (under 20 degrees of steering wheel turn). Efforts may be said to be "flat on center." ^ Under 20 degrees of turn, most of the turning effort that builds up comes from the mesh of gear teeth in the steering gear. In this range, the steering wheel is not yet turned enough to feel the effort from the self-aligning forces at the road wheel or tire patch. ^ In the diagnosis of a steering or alignment concern, it is important to understand the difference between wander and poor groove feel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment Front Alignment: Service and Repair Camber and Caster Adjustment Front Camber and Caster Adjustment Front NOTE: Air suspension vehicles must be at trim ride height prior to measuring or adjusting the caster, camber or toe. 1. Using alignment equipment and the manufacturers instructions, measure the front caster and camber. ^ Refer to Alignment Specifications for optimal alignment settings. ^ If the caster and camber values are not within specification, go to the next step. 2. Remove and discard the lower arm front and rear nuts and bolts. 3. NOTE: New lower arm front and rear bolts must be installed with cam bolt kits (2L1Z-3B236-AC for front bushing; and 2L1Z-3B236-AD for rear bushing), to allow for adjustment of the arm in the frame slot. The vehicle should be supported by the frame to ease movement of the lower arm in the slot. Install the cam bolt kit and loosely install the nut. 4. To adjust the caster and camber, refer to the following chart. ^ Adjustments that require moving the front and the rear of the lower arm should be made equally. 5. While holding the cam bolt, tighten the nut to 270 Nm (199 ft. lbs.). 6. Cheek and, if necessary, adjust the front toe. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment Front > Page 2506 Alignment: Service and Repair Front Toe Adjustment Front Toe Adjustment NOTE: Air suspension vehicles must be at trim ride height prior to measuring or adjusting the caster, camber or toe. 1. Using alignment equipment and the manufacturers instructions, measure the front toe. ^ Refer to Alignment Specifications for optimal alignment settings. ^ If the front toe values are not within specification, go to the next step. 2. Start the engine and center the steering wheel. 3. Turn the engine off and, using a suitable steering wheel holding device, lock the steering wheel in the straight-ahead position. 4. Remove the steering gear bellows clamp(s). 5. Loosen the tie-rod end jam nut(s). 6. NOTE: Do not allow the steering gear bellows to twist while rotating the tie-rod. Rotate the tie-rod(s) to achieve the desired toe setting. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment Front > Page 2507 7. CAUTION: Make sure to hold the tie-rod end stationary while tightening the jam nut or damage to the boot can occur. NOTE: Make sure that the toe settings are not disturbed while tightening the jam nuts. Tighten the tie-rod end jam nut(s) to 103 Nm (76 ft. lbs.). 8. Install the steering gear bellows clamp(s). 9. Start the engine and center the steering wheel. ^ Recheck the toe settings and adjust as necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment Front > Page 2508 Alignment: Service and Repair Camber Adjustment - Rear Camber Adjustment - Rear NOTE: Air suspension vehicles must be at trim ride height prior to measuring or adjusting the rear camber or toe. 1. Using alignment equipment and the manufacturers instructions, measure the rear caster. ^ Refer to Alignment Specifications for optimal alignment settings. ^ If the rear caster value is not within specification, go to the next step. 2. Determine desired camber adjustment (subtract the specified camber angle from the measured camber angle). 3. Mark a scribe line on the upper arm-to-wheel knuckle bolt head and upper arm. Desired Camber Adjustment (In Degrees) (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment Front > Page 2509 Desired Camber Adjustment (In Degrees) (Part 2) 4. Use the following table to determine the camber adjustment required. Obtained by subtracting the specified camber angle from the measure camber angle. 5. Remove the upper arm-to-knuckle nut and install a new one until snug. 6. NOTE: Support the vehicle at the lower arm to ease the wheel knuckle movement in the upper arm slot. Position the upper arm-to-knuckle bolt in the upper arm slot as required to adjust the camber angle to the value obtained in Step 4. 7. Tighten the upper arm-to-knuckle nut to 150 Nm (111 ft. lbs.). 8. Recheck the camber setting, adjust as necessary. 9. Check and, if necessary, adjust the rear toe. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment Front > Page 2510 Alignment: Service and Repair Rear Toe Adjustment Rear Toe Adjustment NOTE: Air suspension vehicles must be at trim ride height prior to measuring or adjusting the rear toe. 1. Using alignment equipment and the manufacturers instructions, measure the rear toe. ^ Refer to Alignment Specifications for optimal alignment settings. ^ If the rear toe values are not within specification, go to the next step. 2. Loosen the toe link jam nut(s). 3. Rotate the toe link tie-rod to achieve the desired toe setting. 4. NOTE: Make sure the toe settings are not disturbed while tightening the jam nuts. Tighten the toe link jam nut(s) to 115 Nm (85 ft. lbs.). 5. Recheck the rear toe setting, adjust as necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment Front > Page 2511 Alignment: Service and Repair Ride Height Adjustments Ride Height Adjustments Special Tools Inflation and Deflation of the Air Suspension System 1. NOTE: Make sure that the air suspension switch is in the ON position. NOTE: Make sure that a battery voltage of at least 11 volts is maintained while carrying out this procedure. Turn the ignition switch to the ON position. 2. Connect the diagnostic tool to the data link connector (DLC). 3. Select Air Suspension Control Module under Active Command Mode. 4. Follow the diagnostic tool directions to lift or vent the front or rear suspension. Calibration Ride Height Resetting 1. NOTE: Make sure that the air suspension switch is in the ON position. NOTE: Make sure that a battery voltage of at least 11 volts is maintained while carrying out this procedure. Turn the ignition to the OFF position. Exit the vehicle, close all doors and allow the system to vent the vehicle down to kneel height (approximately 45 seconds). 2. With the ignition in the ON position, shift the vehicle into DRIVE and then back to PARK. Exit the vehicle, close all doors and allow the vehicle to pump to trim (approximately 45 seconds). 3. Measure the ride height. 4. Open the LF door. 5. Connect the diagnostic tool to the data link connector (DLC). 6. While outside of the vehicle, select the correct vehicle year, model and engine type. 7. Select vehicle dynamic module (VDM). 8. Using the active command mode, vent or lift the vehicle to achieve the correct ride height. 9. Select the "Save Calibration Values (Store Ride Height)" diagnostic tool command to calibrate the VDM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Item....................................................................................................................................................... ..............................................................Specification Fuel Pressure Key on, engine off................................................................................................................................. .............................................240-310 kPa (35-45 psi) Engine running................................................. ..................................................................................................................................193-310 kPa (28-45 psi) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Measured/PID Values Hot Idle Speed ..................................................................................................................................... ....................................................... 600-650 RPM Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 AIR CLEANER INTAKE PIPE Exploded View Removal and Installation 1. Remove the air cleaner element. 2. Reach into the opening of the air cleaner assembly and depress the locking tab on the air cleaner intake pipe to release the air cleaner intake pipe from the air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 2523 3. Remove the air cleaner intake tube assembly. 4. CAUTION: The air cleaner intake pipe should be securely sealed to prevent unusual engine noise. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair AIR CLEANER ELEMENT Exploded View Removal and Installation 1. Release the retaining clips and remove the air cleaner element tray. 2. Remove the air cleaner element from the air cleaner element tray. 3. CAUTION: The air cleaner element tray must be fully seated to the air cleaner housing. Failure to do so will result in unusual engine noise. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The electrical connector is located on the LH frame rail under the driver side door. Disconnect the electrical connector. 3. Start the engine and allow it to idle until it stalls. 4. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail pressure has been released. 5. Turn the ignition switch to the OFF position. 6. When fuel system service is complete, connect the electrical connector. 7. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 8. Install the diagnostic tool. Turn the key ON with the engine OFF. Cycle the key OFF, then ON. Select the appropriate vehicle and engine qualifier. Clear all diagnostic trouble codes (DTCs) and carry out a PCM reset. 9. Start the vehicle and check the fuel system for leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Firing order........................................................................................................................................... ......................................................... 1-3-7-2-6-5-4-8 Eight separate ignition coils: - are mounted directly above each spark plug. - are controlled by the powertrain control module (PCM) for correct firing sequence. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Item ...................................................................................................................................................... ............................................................ Specification Firing order........................................................................................................................................... ......................................................... 1-3-7-2-6-5-4-8 Eight separate ignition coils: - are mounted directly above each spark plug. - are controlled by the powertrain control module (PCM) for correct firing sequence. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions Spark Plug: Technical Service Bulletins Ignition System - Spark Plug Removal Instructions TSB 08-7-6 04/14/08 SPARK PLUG REMOVAL INSTRUCTIONS - 4.6L 3V/5.4L 3V16.8L 3V FORD: 2005-2008 Mustang 2004-2008 F-150 2005-2008 Expedition, F-Super Duty 2006-2008 Explorer, F-53 Motorhome Chassis 2007-2008 Explorer Sport Trac LINCOLN: 2005-2008 Navigator 2006-2008 Mark LT MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-1-9 to update Vehicle Applications, Service Procedure and Part List. ISSUE Some 2004-2008 F-150, 2006-2008 Mark LT, 2005-2008 F-Super Duty, Expedition, and Navigator, with 5.4L 3-V engine; 2005-2008 Mustang, 2006-2008 Explorer, Mountaineer, and 2007-2008 Explorer Sport Trac with 4.6L 3-V engine; 2005-2008 F-Super Duty, 2006-2008 and F-Stripped Chassis, with 6.8L 3-V engine may experience difficulty with spark plug removal. This may cause damage to the spark plug and leave part of the spark plug in the cylinder head. Affected engine build dates are as follows: 5.4L 3-V and 6.8L 3-V before 10/9/07, 4.6L 3-V before 11/30/07. ACTION Refer to the following Service Procedure for techniques to remove the spark plugs and extract broken spark plugs. SERVICE PROCEDURE The engine build date can be read on the left hand cam cover information sticker. To remove spark plugs without damage, it is necessary to adhere exactly to this procedure before removal is attempted. CAUTION DO NOT REMOVE PLUGS WHEN THE ENGINE IS WARM OR HOT. THE ENGINE MUST BE AT ROOM TEMPERATURE WHEN PERFORMING SPARK PLUG SERVICE. REMOVING THE SPARK PLUGS FROM A WARM/HOT ENGINE INCREASES THE CHANCE THE THREADS COULD BE DAMAGED. Spark Plug Removal Procedure 1. Remove the coil-on-plug assemblies and thoroughly blow out the spark plug wells and surrounding valve cover area with compressed air. 2. Back out the spark plugs no more than 1/8 to 1/4 of a turn. Using Motorcraft(R) Carburetor Tune-Up Cleaner, fill the spark plug well just above where the jamb nut hex sits (1/2 - 3/4 teaspoon). A minimum period of 15 minutes of soak time is required. The cleaner will wick down to the ground electrode shield and soften the carbon deposits in this time. DO NOT WORK the spark plug back and forth at this point. NOTE COMPLETELY REVIEW THE PRODUCT LABEL FOR THE MOTORCRAFT CARBURETOR TUNE-UP CLEANER PRODUCT - USE AT ROOM TEMPERATURE AND SHAKE WELL. CAUTION EXCESSIVE MOTORCRAFT(R) CARBURETOR TUNE-UP CLEANER, OR REPEATING THE PROCESS SEVERAL TIMES WITH TOO MUCH CLEANER FLUID, COULD INTRODUCE ENOUGH LIQUID VOLUME TO HYDRO-LOCK THE ENGINE. CAUTION DO NOT USE AIR OR POWER TOOLS FOR SPARK PLUG REMOVAL. SPARK PLUGS MUST ONLY BE REMOVED WITH HAND TOOLS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2542 3. Tighten, and then loosen the spark plug, working the plug back and forth. Some screeching and high effort may be noticed. The expected removal torque is about 33 lb-ft (45 N.m). Repeat the back and forth turning as needed until turning effort is reduced, and remove the spark plugs. NOTE NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT HIGH TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD. DO NOT COAT THE ELECTRODE STRAP. (Figure 1) Separated/Broken Spark Plug Removal If the spark plug separates after following the Spark Plug Removal Procedure, it will fail in one of three modes. Refer to the appropriate removal procedure as required. a. Mode 1: The ground electrode shield is left behind as an empty shell. (Figure 2) b. Mode 2: The entire porcelain insulator and ground electrode shield remains in the cylinder head. (Figure 3) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2543 c. Mode 3: The upper section of porcelain broke off with remaining porcelain left inside the ground shield. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2544 Flowchart of procedure. (Figure 5) Mode 1 Procedure: Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2545 Use Rotunda special service tool 303-1203 to remove an empty ground electrode shield from the cylinder head. (Figure 6) NOTE THIS TOOL IS ONLY DESIGNED TO WORK WITH AN EMPTY GROUND ELECTRODE SHIELD. IF PORCELAIN REMAINS, PROCEED TO MODE 2 OR 3 REMOVAL. 1. Modify vacuum cap to a 3/8" (10 mm) length for each ground electrode shield that needs to be removed. (Figure 7) 2. Use the installation rod (J) provided with service tool 303-1203 update to install the modified vacuum cap. Push the cap into the ground shield down to the electrode strap. This will plug and protect the combustion chamber from contamination. (Figure 7) 3. Thread-tap the ground electrode shield using a 9.0 x 1.0 mm plug tap (tap profile is about 3-4 reduced diameter threads on the tip end). a. Coat the end of the tap with general purpose grease. (Figure 8) b. Turn the tap about 3 to 4 turns into the ground electrode shield. Back the tap up frequently to break chips and avoid cut material from coiling-up in the spark plug well. A tap socket adaptor (K) is provided with service tool 303-1203 update to connect the tap to a 3/8" socket Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2546 drive. CAUTION DO NOT ATTEMPT TO REMOVE THE GROUND ELECTRODE SHIELD WITH THE TAP AND WRENCH. THE TAP MAY BREAK IF THIS IS ATTEMPTED. 4. Thread Rotunda special service tool 303-1203 into the ground electrode shield. (Figure 9) a. Install the stepped end of the tool pilot bushing into the spark plug well ensuring it bottoms out. b. Screw the center shank into the ground electrode shield. Do not over tighten the shank, to prevent thread stripping. c. Install the nylon washer and jack nut until finger tight. d. Turn the jack nut until the ground electrode is freed from the cavity and withdraw the tool assembly. NOTE NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD. DO NOT COAT THE ELECTRODE STRAP. Mode 2 Procedure: 1. Add an additional 1/2 teaspoon Motorcraft® Carburetor Tune-Up Cleaner fluid into spark plug well and allow 15 minutes of soak time. 2. Using long-reach nose pliers grasp and remove the porcelain with an up and down motion taking care not to fracture the porcelain. 3. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder head. Mode 3 Procedure: CAUTION DO NOT DRIVE PORCELAIN DOWN INTO THE GROUND SHIELD WITH A PUNCH AS FRAGMENTS MAY ENTER THE COMBUSTION CHAMBER. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2547 Use Rotunda special service tool kit 303-1398 to remove porcelain broken inside the ground electrode shield. (FIGURE 10) Porcelain Removal - Preparation CAUTION THE ENGINE AND THE BONDING ADHESIVE MUST BE ROOM TEMPERATURE OF 70 °F (21 °C) OR HIGHER FOR PROPER CURE AND BOND STRENGTH. VERIFY EXPIRATION DATE OF ADHESIVE. CAUTION DO NOT REUSE PINS. THIS ENSURES THE CORRECT SURFACE CHARACTERISTICS FOR BONDING. 1. Remove any remaining electrode material from broken porcelain with long nose reach pliers. 2. Spray Motorcraft® Metal Brake Parts Cleaner into the porcelain hole for 2-4 seconds using the straw nozzle supplied with the brake cleaner can. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2548 3. Insert a pin (A) into the collet (B). Screw the collet onto the threaded rod (C). Install the assembled collet, pin, and threaded rod into the steel tool pilot (F). (Figures 11 and 12) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2549 4. Retract the collet and pin into the steel tool pilot, protecting the pin. (Figures 13 and 14) NOTE PIN TIP DAMAGE OR BENT PINS WILL PREVENT INSERTION INTO THE PORCELAIN. 5. Insert the completed assembly into the spark plug well and fully engage the pin into the porcelain. (Figure 15) 6. Spray Motorcraft(R) Metal Brake Parts Cleaner 2-4 seconds between the spark plug well and steel tool pilot. The steel tool pilot must be lifted up approximately 1/2" to allow brake cleaner to flood the porcelain and pin. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2550 7. Scrub the porcelain inside diameter by moving the threaded rod up and down vigorously. Take care making sure the pin does not disengage the porcelain. (Figure 16). 8. Repeat Steps 6 and 7. 9. Remove the tool assembly. Again flood the porcelain with Motorcraft(R) Metal Brake Parts Cleaner for 2-4 seconds, then blow out the entire spark plug well and porcelain with dry compressed air. NOTE CLEAN AND DRY COMPONENTS ARE KEY TO BONDING THE PIN TO THE PORCELAIN. 10. Repeat Steps 1-9 to prepare remaining porcelain fragments as needed. 11. Disassemble the collet and pin from the threaded rod. Dry the tools thoroughly with dry compressed air. Porcelain Removal - Bonding Process CAUTION USE CARE TO PREVENT BONDING AGENT FROM CONTACTING THREADS IN CYLINDER HEAD. NOTE WORKING TIME LIMIT OF LOCTITE(R) 638(TM) RETAINING COMPOUND IS 5 MINUTES. 1. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to opposite sides of a clean and dry applicator (H). Excessive amounts of Loctite(R) 638(TM) are being used if it drips off the applicator. (Figure 17) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2551 2. Insert applicator into the porcelain and move applicator up and down 1/2" (13 mm) while turning to spread the Loctite® 638TM on the inside of the porcelain. (Figure 18). 3. Add additional Loctite(R) 638(TM), repeating Steps 1 and 2. 4. Clean the applicator with Motorcraft(R) Metal Brake Parts Cleaner before the bonding agent starts to cure. 5. Reassemble a dry and clean collet and pin assembly. 6. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to the pin. Excessive amounts of Loctite® 638TMare being used if it drips off the pin. 7. Retract the collet and pin into the steel tool pilot to protect the Loctite(R) 638(TM) coated pin. 8. Insert the completed assembly into spark plug well and fully engage the pin into the porcelain with a twisting motion to spread the bonding agent. 9. Add additional Loctite® 638TM, repeating Steps 6-8. 10. Leave the pin fully inserted in the porcelain while the adhesive cures. Replace the steel tool pilot with the aluminum alignment sleeve (G), Figure 9, to support the threaded rod while the adhesive cures if additional porcelain fragments are present in other cylinders. (Figure 19). CAUTION A MINIMUM 1 HOUR CURING TIME AT 70 °F (21 °C) DEGREES IS REQUIRED BEFORE EXTRACTION IS ATTEMPTED. 11. Allow the Loctite(R) 638(TM) to cure for a minimum of one hour at 70 °F (21 °C). 12. Repeat the bonding process for remaining cylinders as needed. Porcelain Removal - Extraction 1. After a minimum of one hour curing at 70 °F (21 °C), install the steel pilot tool over the threaded rod. 2. Install the washer and jack nut until finger tight against the tool pilot bushing. CAUTION ONLY THE STEEL PILOT TOOL IS ACCEPTABLE FOR USE IN PORCELAIN REMOVAL. 3. While holding the end of the threaded rod with a wrench, tighten the jack nut until the porcelain is free of the ground electrode. 4. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder head. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2552 NOTE NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD. DO NOT COAT THE ELECTRODE STRAP. (FIGURE 7) Porcelain Removal - Pin Slipped Out In the unlikely event that the pin does not remove the broken porcelain, this process can be repeated. Key elements to success are: ^ Clean and dry porcelain ^ Sufficient Loctite® 638TM Retaining Compound spread uniformly ^ Loctite(R) 638(TM) cure time and temperature ^ Preventing the threaded rod from rotating while removing the porcelain Replacement Supplies Replacement kit components and additional kit consumables (Loctite(R) 638TM Retaining Compound and pins) can be obtained by calling 1-800-ROTUNDA, Option 5. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT080706 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 12405 01 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark Plug Gap Spark Plug Gap ............................................................................................................................................................. 0.040 - 0.050 inch (1.02 - 1.27 mm) NOTE: Spark plug gap not adjustable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 2555 Spark Plug: Specifications Spark Plug Torque Spark Plugs ......................................................................................................................................... ................................................... 34 Nm (25.0 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2556 Spark Plug: Application and ID Spark Plug ........................................................................................................................................... ...................................................................... PZT-2F Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2557 Spark Plug: Service and Repair SPARK PLUGS Engine Ignition - RH Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2558 Engine Ignition - LH Exploded View Removal and Installation 1. Remove the ignition coil-on-plug. 2. NOTE: - Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs. - If an original spark plug is used, make sure it is installed in the same cylinder from which it was taken. New spark plugs can be used in any cylinder. Remove the spark plugs. To install, tighten to 34 Nm (25 lb-ft). 3. Inspect the spark plugs. Install new spark plugs as necessary. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications GENERAL SPECIFICATIONS Compression Pressure Limit Chart (Part 1) Compression Pressure Limit Chart (Part 2) The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2562 Compression Check: Testing and Inspection Compression Test-Compression Gauge Check 1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the battery is correctly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of 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 The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart (Part 1) Compression Pressure Limit Chart (Part 2) Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2563 Compression Test-Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications This engine is equipped with hydraulic valve lifters. No adjustment is required. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Locations Drive Belt: Locations Accessory Drive Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Locations > Page 2570 Drive Belt: Diagrams Accessory Drive Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Locations > Page 2571 Drive Belt: Description and Operation Accessory Drive The accessory drive system: - has a single serpentine drive belt (6 ribs). - has 3 idler pulleys. - has an automatic belt tensioner. is not adjustable. The accessory drive system provides power to operate components which power other systems. These could include components such as the generator, power steering pump, and A/C compressor. Each of these components is equipped with a pulley which is driven by the accessory drive belt. The accessory drive belt is driven by the engine crankshaft pulley. One or more idler pulleys may be provided to facilitate belt routing and alignment. The automatic belt tensioner maintains correct belt tension and compensates for component wear and changes in system load. System load changes can be caused by the A/C compressor clutch engaging and disengaging, or demand changes on other systems powered by the accessory drive belt. To maintain correct operation of this stem, it is critical that the correct length drive belt be installed. The pulleys must also be correctly aligned and kept clean. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Drive Belt: Initial Inspection and Diagnostic Overview Accessory Drive Inspection and Verification CAUTION: Under no circumstances should the accessory drive belt, tensioner or pulleys be lubricated as potential damage to the belt material and tensioner damping mechanism will occur. Do not apply any fluids or belt dressing to the accessory drive belt or pulleys. 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical damage. Visual Inspection Chart 3. Eliminate all other non-belt related noises that could cause belt misdiagnosis, such as A/C compressor engagement chirp, power steering cavitations at low temperatures, variable camshaft timing (VCT) tick or generator whine. 4. If a concern is found, correct the condition before proceeding to the next step. V-Ribbed Serpentine Drive Belt With Cracks Across Ribs 5. NOTE: Up to 15 cracks in a rib over a distance of 100 mm (4.0 inch) can be considered acceptable. If damage exceeds the acceptable limit or any chunks are found to be missing from the ribs, a new belt must be installed. Check the belt for cracks. Up to 15 cracks in a rib over a distance of 100 mm (4.0 inch) can be considered acceptable. If cracks exceed this standard, install a new belt. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2574 V-Ribbed Serpentine Belt With Piling 6. The condition of the V-ribbed drive belt should be compared against the illustration and appropriate action taken. 1 Small scattered deposits of rubber material. This is not a concern, therefore, installation of a new belt is not required. 2 Longer deposit areas building up to 50 percent of the rib height. This is not considered a concern but it can result in excessive noise. If noise is apparent, install a new belt. 3 Heavy deposits building up along the grooves resulting in a possible noise and belt stability concern. If heavy deposits are apparent, install a new belt. V-Ribbed Serpentine Belt With Chunks of Rib Missing 7. There should be no chunks missing from the belt ribs. If the belt shows any evidence of this, install a new accessory drive belt. 8. If the concern is not visually evident, verify the symptom and GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2575 Drive Belt: Symptom Related Diagnostic Procedures Symptom Chart Symptom Chart (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2576 Symptom Chart (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2577 Drive Belt: Component Tests and General Diagnostics Component Tests Drive Belt Noise/Flutter Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a damaged or an incorrectly aligned grooved pulley. To correct, determine the area where the noise comes from. Check each of the pulleys in that area with a straightedge to the crankshaft pulley. Look for accessory pulleys out of position in the fore/aft direction or at an angle to the straightedge. CAUTION: Do not apply any fluids or belt dressing to the accessory drive belt or pulleys. Drive belt squeal may be an intermittent or constant noise that occurs when the drive belt slips on an accessory pulley under certain conditions. A short intermittent squeal may occur during engine start-up and shut down or during very rapid engine acceleration and decelerations, such as: ^ wide open throttle 1-2 and 2-3 shifts or 2-3 and 3-4 back out shifts on automatic transmissions. ^ wide open throttle 1-2 and 2-3 shifts and any combination of rapid downshifting on manual transmissions. These special short-term transient events are expected, and are due to the higher system inertias required to meet the electrical and cooling demands on today's vehicle systems. Constant or re-occurring drive belt squeal can occur under these 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 discharged and suction pressure that occurs after several minutes) exceeds specifications. ^ if any of the accessories are damaged or have a worn or damaged bearing. All accessories should be rotatable by hand in the unloaded condition, if not, inspect the accessory. ^ if there is evidence of fluid contamination on the accessory drive belt. When the drive belt has been exposed to fluid contamination during vehicle operation, such as leaks from the power steering system, A/C system or cooling system, clean all pulleys with soap and water, rinse with clean water and install a new accessory drive belt. If the drive belt has been exposed to fluids in a localized area during routine vehicle service, such as replacement of hoses or fluids, the drive belt and pulleys should be washed with soap and water immediately (prior to starting the engine), and rinsed with clean water. ^ if the accessory drive belt is too long. A drive belt that is too long will allow the accessory drive belt tensioner arm to go all the way to the arm travel stop under certain load conditions, which will release tension to the drive belt. If the accessory drive belt tensioner indicator is outside the normal installation wear range window, install a new accessory drive belt. ^ NOTE: The accessory drive belt tensioner arm should rotate freely without binding. Install a new accessory drive belt tensioner if the drive belt tensioner is worn or damaged. Incorrect Drive Belt Installation CAUTION: Incorrect accessory drive belt installation will cause excessive drive belt wear and can cause the drive belt to come off the pulleys. Non-standard accessory drive belts can track differently or incorrectly. If an accessory drive belt tracks incorrectly, install a new accessory drive belt to avoid performance failure or loss of the drive belt. Incorrect Installation Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2578 Correct Installation With the engine running, check accessory drive belt tracking on all pulleys. If the edge of the accessory drive belt rides beyond the edge of the pulleys, noise and premature wear will occur. Make sure the accessory drive belt rides correctly on the pulley. If an accessory drive belt tracking condition exists, proceed with these steps: ^ Visually check the accessory drive belt tensioner for damage, especially the mounting pad surface. If the accessory drive belt tensioner is not installed correctly, the mounting surface pad will be out of position. This will result in chirp and squeal noises. ^ With the engine running, visually observe the grooves in the pulleys (not the pulley flanges or the pulley forward faces) for excessive wobble. Install new components as necessary. ^ Check all accessories, mounting brackets and the accessory drive belt tensioner for any interference that would prevent the component from mounting correctly. Correct any interference condition and recheck the accessory drive belt tracking. Tighten all accessories, mounting brackets and accessory drive belt tensioner retaining hardware to specification. Recheck the accessory drive belt tracking. Belt Tensioner - Mechanical The only mechanical check that needs to be made is a check for tensioner stick grab or bind. 1. With the engine OFF, check routing of the accessory drive belt. 2. NOTE: The accessory drive belt tensioner spring is very strong and requires substantial force to release. Using a suitable, commercially available serpentine belt tensioner release tool, release the tension on the belt and detach the accessory drive belt in the area of the tensioner. 3. Using the suitable, commercially available serpentine belt tensioner release tool, move the tensioner from its relaxed position, through its full stroke and back to the relaxed position to make sure there is no stick, grab or bind, and to make sure that there is tension on the tensioner spring. 4. Rotate the tensioner pulley by hand and check for a binding, contaminated or seized condition. Install a new accessory drive belt tensioner if necessary. 5. Inspect the area surrounding the accessory drive belt tensioner for oil leaks or contamination and repair any leaks. Install a new accessory drive belt tensioner as necessary. 6. If the accessory drive belt tensioner meets the above criteria, proceed to testing the tensioner dynamically. If the accessory drive belt tensioner does not meet the above criteria, install a new tensioner. Belt Tensioner - Dynamics The accessory drive belt tensioner can be checked dynamically as follows: 1. With the engine running, observe the accessory drive belt tensioner movement. The accessory drive tensioner should move (respond) when the air conditioning clutch cycles (if equipped), or when the engine is accelerated rapidly. If the accessory drive belt tensioner movement is excessive without air conditioning clutch cycling or engine acceleration, check belt rideout. Excessive belt rideout (uneven depth of grooves in the belt) can cause excessive accessory drive belt tensioner movement. Check rideout condition by installing a new belt. If excessive accessory drive belt tensioner movement still exists, install a new accessory drive belt tensioner. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 2579 Drive Belt: Service and Repair Accessory Drive 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 (V8-5.4L VIN 5 (2006)) 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 AIR CLEANER INTAKE PIPE Exploded View Removal and Installation 1. Remove the air cleaner element. 2. Reach into the opening of the air cleaner assembly and depress the locking tab on the air cleaner intake pipe to release the air cleaner intake pipe from the air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 2585 3. Remove the air cleaner intake tube assembly. 4. CAUTION: The air cleaner intake pipe should be securely sealed to prevent unusual engine noise. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair AIR CLEANER ELEMENT Exploded View Removal and Installation 1. Release the retaining clips and remove the air cleaner element tray. 2. Remove the air cleaner element from the air cleaner element tray. 3. CAUTION: The air cleaner element tray must be fully seated to the air cleaner housing. Failure to do so will result in unusual engine noise. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair NOTE: The air distribution system of this vehicle cannot be equipped with a cabin air filter. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Transmission Fluid In-Line Filter Fluid Filter - A/T: Service and Repair Transmission Fluid In-Line Filter 4R70E/4R75E Automatic Transmission Transmission Fluid In-Line Filter Special Tools Transmission Fluid In-line Filter with an OTA cooler NOTE: Use the following guidelines for installing the transmission fluid in-line filter: ^ If the transmission was overhauled and the vehicle was equipped with an in-line fluid filter, install a new in-line fluid filter. ^ If the transmission was overhauled and the vehicle was not equipped with an in-line fluid filter, install a new in-line fluid filter kit. ^ If the transmission is being installed for a non-internal repair, do not install an in-line filter or filter kit. ^ If installing a new or a Ford-authorized remanufactured transmission, install the in-line transmission fluid filter that is supplied. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If equipped, remove the bolts and the skid plate. 3. Remove the section of the rubber hose and steel line as illustrated. ^ Clean and de-burr the end of the steel line. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Transmission Fluid In-Line Filter > Page 2596 4. NOTE: Be sure the cooler tube is fully seated in the body of the fitting before final tightening of the ferrule nut. Install the tubing ferrule hose assembly connector onto the end of the steel fluid cooler tube. Finger-tighten the ferrule nut, then tighten the nut an additional 1-1/2 turns to seat the ferrule in the connector. 5. CAUTION: The filter has a bypass valve in it. The red arrow on the filter indicates the direction of fluid flow through the filter. The filter must be installed in the fluid cooler return line with the red arrow on the filter pointing away from the transmission fluid cooler and toward the transmission (the return line has fluid coming out of the cooler going to the transmission). If the fluid filter is not installed correctly, it will cause internal transmission damage. CAUTION: Do not install any rubber hoses or steel tubing with a bend entering the filter greater than 60 degrees. Using a suitable length of hose install the filter. Tighten the hose clamps. 6. Clean a section of the transmission fluid pan and install the sticker. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Transmission Fluid In-Line Filter > Page 2597 7. If equipped, install the skid plate and the bolts. 8. Fill the transmission with clean automatic transmission fluid. ^ Verify for correct operation. ^ Check the filter for leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Transmission Fluid In-Line Filter > Page 2598 Fluid Filter - A/T: Service and Repair Transmission Fluid In-Line Filter - Without an OTA Cooler 4R70E/4R75E Automatic Transmission Transmission Fluid In-line Filter - without an OTA cooler NOTE: Use the following guidelines for installing the transmission fluid in-line filter: ^ If the transmission was overhauled and the vehicle was equipped with an in-line fluid filter, install a new in-line fluid filter. ^ If the transmission was overhauled and the vehicle was not equipped with an in-line fluid filter, install a new in-line fluid filter kit. ^ If the transmission is being installed for a non-internal repair, do not install an in-line filter or filter kit. ^ If installing a new or a Ford-authorized remanufactured transmission, install the in-line transmission fluid filter that is supplied. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the cooler tubes retainers. 3. Remove the section of the steel tube as illustrated. ^ Clean and de-burr the end of the steel tubes. 4. NOTE: Be sure the cooler tube is fully seated in the body of the fitting before final tightening of the ferrule nut. Install the tubing ferrule hose assembly connector onto the end of the steel fluid cooler tubes. Finger-tighten the ferrule nut, then tighten the nut an additional 1-1/2 turns to seat the ferrule in the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Transmission Fluid In-Line Filter > Page 2599 5. CAUTION: The filter has a bypass valve in it. The red arrow on the filter indicates the direction of fluid flow through the filter. The filter must be installed in the fluid cooler return line with the red arrow on the filter pointing away from the transmission fluid cooler and toward the transmission (the return line has fluid coming out of the cooler going to the transmission). If the fluid filter is not installed correctly, it will cause internal transmission damage. CAUTION: Do not install any rubber hoses or steel tubing with a bend entering the filter greater than 60 degrees. Using a suitable length of hose install the filter. Tighten the hose clamps. 6. Install one cooler tube retainer as Illustrated. 7. Secure the cooler tubes together with a tie strap. 8. Clean a section of the transmission fluid pan and install the sticker. 9. Fill the transmission with clean automatic transmission fluid. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Transmission Fluid In-Line Filter > Page 2600 ^ Verify for correct operation. ^ Check the filter for leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Transmission Fluid In-Line Filter > Page 2601 Fluid Filter - A/T: Service and Repair Fluid Pan, Gasket and Filter 4R70E/4R75E Automatic Transmission Fluid Pan, Gasket and Filter Material Removal CAUTION: Do not use any supplemental transmission fluid additives or cleaning agents. The use of these products could cause internal transmission components to fail; this will effect the operation of the transmission. Use of a fluid other than specified could result in transmission failure. NOTE: Normal maintenance requires periodic automatic transmission fluid changes. If a major repair, such as a clutch, band, bearing, etc., is required, the automatic transmission will need to be removed for repair. The transmission fluid needs to be changed if evidence of fluid contamination is found. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid. ^ Loosen the transmission fluid pan bolts and allow fluid to drain. After fluid is drained remove the bolts. 3. Remove the transmission fluid pan and transmission fluid pan gasket. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Transmission Fluid In-Line Filter > Page 2602 4. Pull down evenly and remove the transmission fluid filter and seal. 5. Clean and inspect the transmission fluid pan, gasket and magnet. Installation 1. 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. Install a new fluid filter and seal as required. 2. Position the pan magnet into the transmission fluid pan. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Transmission Fluid In-Line Filter > Page 2603 3. 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 and gasket. 2 Install the transmission fluid pan bolts. ^ Tighten to 14 Nm (10 ft. lbs.). 4. NOTE: When filling a dry transmission and converter, start with a minimum of 4.7 liters (5 quarts). Fill the transmission to the correct level with clean automatic transmission fluid. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The electrical connector is located on the LH frame rail under the driver side door. Disconnect the electrical connector. 3. Start the engine and allow it to idle until it stalls. 4. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail pressure has been released. 5. Turn the ignition switch to the OFF position. 6. When fuel system service is complete, connect the electrical connector. 7. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 8. Install the diagnostic tool. Turn the key ON with the engine OFF. Cycle the key OFF, then ON. Select the appropriate vehicle and engine qualifier. Clear all diagnostic trouble codes (DTCs) and carry out a PCM reset. 9. Start the vehicle and check the fuel system for leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 (V8-5.4L VIN 5 (2006)) 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 2617 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 (V8-5.4L VIN 5 (2006)) 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 2618 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 (V8-5.4L VIN 5 (2006)) 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 (V8-5.4L VIN 5 (2006)) 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 2624 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 (V8-5.4L VIN 5 (2006)) 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 2625 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Coupling Heater Hose: Service and Repair Heater Hose Coupling HEATER HOSE COUPLING Remover, Heater Hose Inlet Tube Special Tool(s) Disconnect 1. 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. Depressurize the engine cooling system. 2. Push the heater water hose toward the tube to fully expose the locking tabs. 3. NOTE: When compressing the white coupling retainer, the Heater Hose Disconnect Tool must be perpendicular to and on the highest point of the coupling. Push the special tool over the coupling retainer windows to compress the retainer locking tabs. 4. NOTE: A slight twisting motion while pulling on the heater water hose may be necessary to assist in the removal. Pull the heater water hose away from the heater core tube. 5. Plug the heater water hose. 6. Remove the white coupling retainer from the tube. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Coupling > Page 2628 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 MERPOL(R) meeting Ford specification ESE-M99B144-B or plain water. 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Coupling > Page 2629 Heater Hose: Service and Repair Auxiliary Heater Outlet and Inlet Line AUXILIARY HEATER OUTLET AND INLET LINE Removal CAUTION: To avoid refrigerant loss, clearly differentiate the auxiliary heater lines from the auxiliary refrigerant lines before beginning this procedure. NOTE: - The auxiliary heater inlet and outlet lines are not supplied together as an assembly. The auxiliary heater inlet line and outlet line are each installed from the factory as 1-piece assemblies. The replacement parts are supplied as separate kits containing multiple piece lines for ease of installation. - The following procedure can be used to remove and install 1 or both the auxiliary heater inlet and auxiliary heater outlet lines. If only one auxiliary heater line is to be removed and installed, cut or disconnect only the desired line at the specified points within the procedure. 1. Drain the engine coolant. 2. Remove the RH quarter trim panel. 3. Detach the auxiliary heater lines. 1 Disconnect the heater hose(s). 2 Remove the 2 line bracket bolts. 3 Remove the line bracket. 4. Remove the spare tire. 5. Raise the vehicle. 6. Remove the RH front wheel. 7. Remove the RH fender splash shield. 8. NOTE: If installing only one auxiliary heater line, disconnect only the desired line. Disconnect the heater hose(s). 9. Remove the muffler. 10. Remove the RH catalytic converter. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Coupling > Page 2630 11. Remove the 3 bolts and the heat shield. 12. Remove the bolts. 13. Remove the nut and the line bracket. 14. Remove the bolt and the heat shield. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Coupling > Page 2631 15. Remove the nuts and the remaining line brackets. 16. NOTE: If installing only one auxiliary heater line, cut only the desired line. Assemble and lay out the replacement line(s) in the same position as the existing line(s) and, using a suitable tool, cut the auxiliary heater line(s) in the same position as the fittings on the new line(s). 17. Remove the auxiliary heater line(s) in 3 separate pieces. Installation 1. Partially lower the vehicle. 2. Attach the rear portion of the auxiliary heater lines. 1 Connect the heater hoses. 2 Install the line bracket. 3 Install the bolts. 3. Install the front auxiliary heater line(s) and connect the heater hose(s). - Clean and lubricate the heater hoses with plain water only if needed. 4. Raise the vehicle. 5. NOTE: Loosely connect, but do not tighten, the fittings. Install the middle auxiliary heater line(s). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Coupling > Page 2632 6. Starting from the rear of the vehicle, install the first 3 line brackets. - Tighten to 5 Nm (44 lb-in). 7. Tighten the middle auxiliary heater line fittings. 8. Inspect the auxiliary heater lines for correct installation. Loosen, reposition and tighten as needed. 9. Install the heat shield and the bolts. - Tighten to 15 Nm (11 lb-ft). 10. Install the heat shield and the bolts. - Tighten to 15 Nm (11 lb-ft). 11. Install the RH catalytic converter. 12. Install the muffler. 13. Partially lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Coupling > Page 2633 14. Install the heat shield bolt. - Tighten to 15 Nm (11 lb-ft). 15. Install the line bracket. - Tighten to 5 Nm (44 lb-in). 16. Lower the vehicle. 17. Install the spare tire. 18. Install the RH quarter trim panel. 19. Fill the engine coolant level. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly Hose/Line HVAC: Service and Repair Compressor Manifold and Tube Assembly COMPRESSOR MANIFOLD AND TUBE ASSEMBLY Removal and Installation NOTE: Installation of a new receiver/drier is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. All vehicles 1. Recover the refrigerant. 2. Disconnect the negative and positive battery cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 2638 3. Disconnect the electrical connector. 4. Disconnect the pressure cutoff switch electrical connector. 5. Remove the compressor manifold and tube suction fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). Vehicles with auxiliary A/C 6. Remove the auxiliary evaporator outlet line fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). All vehicles 7. Remove the compressor manifold and tube assembly discharge fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). 8. Loosen the compressor manifold bolt and remove the compressor manifold and tube assembly. - Discard the O-ring seals. - To install, tighten to 20 Nm (15 lb-ft). 9. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 10. Evacuate, leak test and charge the refrigerant system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 2639 Hose/Line HVAC: Service and Repair Auxiliary Evaporator Outlet and Inlet Line AUXILIARY EVAPORATOR OUTLET AND INLET LINE Removal NOTE: - The auxiliary evaporator inlet and outlet lines are not supplied together as an assembly. The auxiliary evaporator inlet line and outlet line are each installed from the factory as 1-piece assemblies. The replacement parts are supplied as separate kits containing multiple piece lines for ease of installation. - The following procedure can be used to remove and install 1 or both the auxiliary evaporator inlet and auxiliary evaporator outlet lines. If only one auxiliary evaporator line is to be removed and installed, cut or disconnect only the desired line at the specified points within the procedure. - Installation of a new receiver/drier is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. 1. Recover the refrigerant. 2. NOTE: If only one auxiliary evaporator line is to be removed, disconnect only the desired line. Remove the nut(s) and disconnect the A/C fitting(s). 3. Remove the RH quarter trim panel. 4. Remove the spare tire. 5. NOTE: Both A/C fittings must be disconnected even if only one line is to be removed. Disconnect the A/C fittings. Install new O-rings seals. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 2640 6. Remove the bolts and the line bracket. 7. Raise the vehicle. 8. Remove the spare tire carrier splash shield. 9. Remove the RH front wheel. 10. Remove the RH fender splash shield. 11. Remove the muffler. 12. Remove the RH catalytic converter. 13. Remove the 3 bolts and the heat shield. 14. Remove the bolts. 15. Remove the nut and the line bracket. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 2641 16. Remove the bolt and the heat shield. 17. Remove the nuts and the remaining line brackets. 18. NOTE: If installing only one auxiliary evaporator line, cut only the desired line. Assemble and lay out the replacement line(s) in the same position as the existing line(s) and, using a suitable tool, cut the auxiliary evaporator line(s) in the same position as the fittings on the new line(s). 19. Remove the auxiliary evaporator line(s) in 3 separate pieces. Installation 1. Partially lower the vehicle to allow access to both the rear auxiliary line fittings and the underside of the vehicle. 2. Position the rear portion of the auxiliary evaporator line(s) and install the line bracket and bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 2642 3. Connect the A/C fittings. - Install new O-ring seals. - Tighten to 8 Nm (71 lb-in). 4. Install the front auxiliary evaporator line(s) and connect the A/C fittings. - Install new O-ring seals. - Tighten to 8 Nm (71 lb-in). 5. Raise the vehicle. 6. NOTE: Loosely connect, but do not tighten, the fittings. Install the middle auxiliary evaporator line(s). 7. Starting from the rear of the vehicle, install the first 3 line brackets. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 2643 - Tighten to 5 Nm (44 lb-in). 8. Tighten the middle auxiliary evaporator line fittings. 9. Inspect the auxiliary evaporator lines for correct installation. Loosen, reposition and tighten as needed. 10. Install the heat shield and the bolts. - Tighten to 15 Nm (11 lb-ft). 11. Install the heat shield and the bolts. - Tighten to 15 Nm (11 lb-ft). 12. Install the RH catalytic converter. 13. Install the muffler. 14. Partially lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 2644 15. Install the heat shield bolt. - To install, tighten to 15 Nm (11 lb-ft). 16. Install the line bracket. - Tighten to 5 Nm (44 lb-in). 17. Install the spare tire carrier splash shield. 18. Install the RH front fender splash shield. 19. Install the RH front wheel. 20. Lower the vehicle. 21. Install the RH quarter trim panel. 22. Install the spare tire. 23. Lubricate the refrigerant system with the correct amount of clean PAG oil. 24. Evacuate, leak test and charge the refrigerant system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line Power Steering Line/Hose: Service and Repair Power Steering Pump to Steering Gear Pressure Line Power Steering Pump to Steering Gear Pressure Line - 4x4 Materials Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line > Page 2649 Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line > Page 2650 Part 2 Removal and Installation CAUTION: While repairing the power steering system, care should be taken to prevent the entry of contaminants or premature failure of the power steering components can result. NOTE: New O-ring seals must be installed any time the lines are disconnected from the steering gear. All vehicles 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 LH quarter trim panel rear. 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. Failure to follow these instructions may result in personal injury. Turn the air suspension switch to the OFF position, if equipped. 2. With the vehicle in NEUTRAL, position it on a hoist. 3. Remove the engine cooling fan. 4. Remove the power steering pump pulley. 5. Disconnect the power steering pressure line-to-pump fitting. Discard the Teflon seal. ^ To install, tighten to 65 Nm (48 ft. lbs.). 6. Remove the 2 bolts and the oil drip shield. ^ To install, tighten to 11 Nm (8 ft. lbs.). 7. Remove the power steering pressure line bracket-to-crossmember bolt. ^ To install, tighten to 11 Nm (8 ft. lbs.). 8. Disconnect the power steering pressure line from the frame rail retainers. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line > Page 2651 9. Remove the power steering pressure line bracket-to-engine nut. ^ To install, tighten to 40 Nm (30 ft. lbs.). Expedition vehicles 10. If equipped disconnect the power steering pressure sensor electrical connector and detach the harness retainer. All vehicles CAUTION: New O-ring seals must be installed any time the lines are disconnected from the steering gear. 11. Remove the power steering line clamp plate bolt and the power steering pressure line. Discard the O-ring seal. 1 To install, tighten to 23 Nm (17 ft. lbs.). 12. To install, reverse the removal procedure. ^ Using the special tool, install a new Teflon O-ring seal on the power steering pressure line-to-pump fitting. ^ Install a new O-ring seal on the clamp plate end of the power steering pressure line. ^ Fill the power steering system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line > Page 2652 Power Steering Line/Hose: Service and Repair Power Steering Fluid Cooler to Power Steering Fluid Reservoir Return Hose Power Steering Fluid Cooler to Power Steering Fluid Reservoir Return Hose Material Removal and Installation CAUTION: While repairing the power steering system, care should be taken to prevent the entry of contaminants or premature failure of the power steering components can result. All vehicles 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 near in the LH rear quarter trim panel. 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. Failure to follow these instructions may result in personal injury. Turn the air suspension switch to the OFF position, if equipped. 2. With the vehicle in NEUTRAL, position it on a hoist. 3. Using a suitable suction device, remove the power steering fluid from the reservoir. 4. Remove the 3 power steering reservoir bolts. ^ To install, tighten to 11 Nm (8 ft. lbs.). 5. Release the clamp, and disconnect power steering return line from the reservoir. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line > Page 2653 Navigator vehicles 6. Remove the pushpins and the deflector shield. All vehicles 7. Release the clamp and disconnect the power steering return line from the power steering cooler. 8. Disconnect the power steering return line from the frame rail retainer and remove the line. 9. To install, reverse the removal procedure. Fill the power steering system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line > Page 2654 Power Steering Line/Hose: Service and Repair Steering Gear to Fluid Cooler Return Hose Steering Gear to Fluid Cooler Return Hose Materials Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line > Page 2655 Part 2 Removal and Installation CAUTION: While repairing the power steering system, care should be taken to prevent the entry of contaminants or premature failure of the power steering components can result. NOTE: New O-ring seals must be installed any time the lines are disconnected from the steering gear. All vehicles 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 LH rear quarter trim panel. 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. Turn the air suspension switch to the OFF position, if equipped. 2. With the vehicle in NEUTRAL, position it on a hoist. Navigator vehicles 3. Remove the pushpins and the deflector shield. All vehicles 4. Release the clamp and disconnect the power steering return line from the power steering cooler. 5. Remove the 2 bolts and the oil drip shield. ^ To install, tighten to 11 Nm (8 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line > Page 2656 CAUTION: New O-ring seals must be installed any time the lines are disconnected from the steering gear. 6. Remove the steering line clamp plate bolt. ^ To install, tighten to 28 Nm (18 ft. lbs.). ^ Discard the steering line O-ring seals. 7. Disconnect the line from frame rail retainers and remove the return line. 8. To install, reverse the removal procedure. ^ Install a new O-ring seals. ^ Fill the power steering system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid Ford P/N .............................................................................................................................................. ..................................................................... PM-1 Ford Specification ................................................ ..................................................................................................................................... ESA-M6C25-A Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications COOLING SYSTEM BASE RADIATOR With aux rear heat ............................................................................................................................... ........................................ 20.7 quarts (19.6 liters) Without aux rear heat ........................................... ....................................................................................................................... 19.4 quarts (18.4 liters) HEAVY DUTY TRAILER TOW RADIATOR With aux rear heat ............................................................................................................................... ........................................ 20.9 quarts (19.8 liters) Without aux rear heat ........................................... ....................................................................................................................... 19.7 quarts (18.6 liters) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 2665 Coolant: Fluid Type Specifications ENGINE COOLANT Motorcraft Premium Gold Engine Coolant (yellow-colored) Ford P/N ............................................................................................................................................................ VC-7-A (U.S., except CA, OR and NM) Ford P/N ............................................................................... .................................................................................................. VC-7-B (CA, OR and NM) Ford Specification ................................................................................................................................ ................................................ WSS-M97B51-A1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid .............................................................................................................................. .............................................. 13.9 quarts (13.1 liters) NOTE: Indicates only approximate dry-fill capacity. Some applications may vary based on cooler size and if equipped with an in-tank cooler. The amount of transmission fluid and fluid level should be set by the indication on the dipsticks normal operating range. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 2670 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Fluid Type ............................................................................................................................................ ............................................. MERCON V XT-5-QM Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission Fluid - A/T: Service and Repair 6HP26 Automatic Transmission Transmission Fluid Cooler Backflushing and Cleaning 6HP26 Automatic Transmission Transmission Fluid Cooler Backflushing and Cleaning Material CAUTION: When internal damage occurs in the transmission, metal particles and clutch plate material can travel into the torque converter and the transmission fluid cooler. These contaminates are a major cause of recurring transmission concerns. To prevent further concerns, remove these contaminates from the cooler lines and install a new cooler before placing the transmission in use. 1. Install a new transmission fluid cooler if any fluid leak are indicated or a major metallic failure is indicated. 2. Using a suitable torque converter/fluid cooler cleaner, flush the fluid cooler and lines. 3. NOTE: Rubber hoses must be attached to the ends of the fluid cooler tubes, to aid in connecting them to the cleaner. Connect the cleaner pressure and return lines appropriately. 1 Connect the pressure line to the fluid cooler inlet tube. 2 Connect the return line to the fluid cooler outlet tube. 3 Place the outlet end of the return line in the fluid tank reservoir. 4. NOTE: Cycling the fluid pump on and off will help dislodge contaminants in the cooler system. Switch the fluid pumps on. Allow the fluid to circulate a minimum of 5 minutes. 5. Switch the fluid pump off. 6. Disconnect the cleaner pressure line at the fluid cooler tube. 7. Using compressed air, blow through the fluid cooler inlet tube until all fluid is removed. 8. Remove the rubber hoses from the fluid cooler tubes. Transmission Fluid Drain and Refill Transmission Fluid Drain and Refill Special Tools Material Drain Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 2673 CAUTION: The fluid fill plug located on the side of the transmission is near the exhaust system. The exhaust will be extremely hot during this procedure. Use care when working near the exhaust and the heat shields. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove and discard the fluid pan drain plug and allow the fluid to drain. Refill 1. Install a new fluid pan drain plug. ^ Tighten to 8 Nm (71 inch lbs.). 2. Remove the fluid fill plug located on the RH rear side of the case, near the transmission electrical connector. 3. CAUTION: The use of any other transmission fluid than specified can result in the transmission failing to operate in a normal manner or Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 2674 transmission failure. Fill the transmission. ^ Add 4.7 liters (5 quarts) of clean automatic transmission fluid to the transmission through the fluid fill hole. Stop when the fluid runs out of the bottom of the hole. 4. Install the fluid fill plug located on the RH rear side of the case, near the transmission electrical connector. ^ Tighten to 35 Nm (26 ft. lbs.). 5. Start the engine. Move the transmission range selector lever through all the gear ranges, checking for engagements. 6. With the special tool connected, the engine idling (600 - 750 rpm) in PARK and the transmission temperature at 30°C - 50°C (86°F - 122°F), check and adjust the transmission fluid level. 7. If more fluid is needed, remove the fluid fill plug on the side of the case and fill with clean automatic transmission fluid until the fluid runs out of the bottom of the hole. Check Fluid Level and Condition Check Fluid Level and Condition Fluid Level Check CAUTION: The vehicle should not be driven if the fluid level is low as internal failure could result. NOTE: If the vehicle has been operated for an extended period at high highway speeds, in city traffic, during hot weather or while pulling a trailer, the fluid must cool down to obtain an accurate reading. NOTE: The transmission fluid temperature must not be allowed to exceed 50°C (122°F) when checking the fluid level. The fluid temperature should be between 30°C - 50°C (86°F - 122°F) closer to 50°C (122°F) when checking the fluid level. This vehicle is not equipped with a fluid level indicator. An incorrect level may affect the transmission operation and can result in transmission failure. Under normal circumstances, the fluid level should not be checked during normal maintenance. If the transmission starts to slip, shifts slowly or shows signs of fluid leaking, the fluid level should be checked. 1. With the transmission in P (PARK), the engine at idle (600 - 750 rpm) and foot pressed on the brake, move the range selector lever through each gear and allow engagement of each gear. Place the transmission range selector lever in the P position. 2. With the engine idling (600 - 750 rpm) in PARK, position it on a hoist. 3. Remove the fluid fill plug located on the side of the transmission case. 4. Partially add fluid until fluid starts to come out. Wait until the fluid stops or just drips from the hole. 5. Install the fluid fill plug. ^ Tighten to 35 Nm (26 ft. lbs.). High Fluid Level CAUTION: A fluid level that is too high can cause the fluid to become aerated due to the churning action of the rotating internal parts. This will Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 2675 cause erratic control pressure, foaming, loss of fluid from the vent tube and possible transmission failure. If an overfill reading is indicated, drain and refill the transmission. Low Fluid Level A low fluid level can result in poor transmission engagement, slipping or failure. This may 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 can result in transmission failure. If fluid must be added, add fluid in 0.5 liter (1/2 quart)increments through the fluid fill plug. Do not overfill the fluid. For fluid type, refer to the specification chart. Fluid Condition Check 1. Check the fluid level. 2. Remove the fluid fill plug and allow the fluid to drip onto a facial tissue and examine the stain. 3. NOTE: The transmission fluid could be 2 different colors. The factory fill fluid is clear. The replacement fluid is red. Observe the color and the odor. The color under normal circumstances should be dark reddish or clear, not black or have a burnt odor. 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 and fluid cooler tubes. A new oil-to-air cooler must be installed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 2676 Fluid - A/T: Service and Repair 4R70E/4R75E Automatic Transmission Transmission Fluid Cooler Backflushing and Cleaning Transmission Fluid Cooler Backflushing and Cleaning Material 1. CAUTION: Do not use any supplemental transmission fluid additives or cleaning agents. The use of these products could cause internal transmission components to fail; this will effect the operation of the transmission. Conduct backflushing with a suitable torque converter/fluid cooler cleaner. Test your equipment to make sure that a vigorous fluid flow is present before proceeding. Install a new filter in the flush equipment if flow is weak or contaminated. 2. If equipped, remove and discard the transmission fluid in-line filter. 3. Remove the transmission fluid cooler bypass valve and install rubber hoses in its place. 4. To aid in attaching the cleaner to the transmission steel cooler lines, connect 2 additional rubber hoses to the transmission end of the steel transmission cooler lines as described below. ^ Connect the cleaner tank pressure line to the steel transmission cooler return line (longest line). ^ Connect a tank return hose to the steel transmission cooler pressure line (shorter line). Place the outlet end of this hose in the tank reservoir. 5. Turn on the pump and allow the fluid to circulate a minimum of 5 minutes (cycling switch on and off will help dislodge contaminants in cooler system). 6. Switch off the pump and disconnect the pressure hose from the transmission cooler return line. 7. Use compressed air to blow out the cooler(s) and lines (blow air into the transmission cooler return line) until all fluid is removed. 8. Remove the rubber return hose from the remaining steel cooler line. 9. Remove the rubber hoses and reinstall the transmission fluid cooler bypass valve. Transmission Fluid Drain and Refill Transmission Fluid Drain and Refill Special Tools Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 2677 special Tools Draining, all vehicles using a suitable flush and fill machine CAUTION: Always refer to the instructions supplied with the flush and fill machine. NOTE: Draining fluid from the transmission by removing only the fluid pan is acceptable for normal or severe duty fluid maintenance. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Use a suitable flush and fill machine to change the fluid. 3. When connecting the flush and fill machine, connect the machine to the fluid cooler tube after the fluid cooler on the cooler return line. This will help remove any foreign material trapped in the fluid coolers. Refill 1. Use only clean automatic transmission fluid. 2. Once the fluid exchange has been completed, disconnect the flush and fill machine. Reconnect any disconnected fluid cooler tubes. 3. With the engine running and the transmission at normal operating temperature 66 - 77°C (150 - 170°F), check and adjust the transmission fluid level and check for any leaks. If fluid is needed, add fluid in increments of 0.24 liter (0.5 pint) until the correct level is achieved (fluid should be in the cross-hatched area of the fluid level indicator). Draining, all vehicles not using a suitable flush and fill machine 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Loosen the transmission fluid pan bolts and allow the fluid to drain. 3. After the fluid has drained, remove the transmission fluid pan. 4. Do not remove the fluid filter. It is not necessary to change the fluid filter during a normal maintenance fluid change. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 2678 5. Clean and inspect the transmission fluid pan, transmission fluid pan gasket and magnet. 6. Thoroughly flush the cooler tubes. Refill 1. Position the magnet into the transmission fluid pan. 2. NOTE: The fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the gasket should be reused. Install the fluid pan and gasket. 1 Position the fluid pan with the gasket in place. 2 Install the bolts. 1 Tighten to 14 Nm (10 ft. lbs.). 3. CAUTION: The use of any other transmission fluid can result in the transmission failing to operate in a normal manner or transmission failure. Fill the transmission. Add 4.7 liters (5 qts) of clean automatic transmission fluid to the transmission through the fluid filler tube. 4. Start the engine. Move the transmission range selector lever through all the gear ranges, checking for engagements. 5. With the engine running and the transmission at normal operating temperature 66 - 77°C (150 - 170°F), check and adjust the transmission fluid level and check for any leaks. If fluid is needed, add fluid in increments of 0.24 liter (0.5 pint) until the correct level is achieved (fluid should be in the cross-hatched area of the fluid level indicator). Check Fluid Level and Condition Check Fluid Level and Condition 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. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 2679 NOTE: If vehicle has been operated for an extended period of time at highway speeds, in city traffic, in hot weather or when 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, shifts 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 drain and refill the transmission. 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 type of transmission fluid other than specified could result in transmission malfunction and/or damage. If fluid needs to be added, add fluid in 0.25L (1/2 pint) increments through the filler tube. Do not overfill the fluid. For fluid type, refer to the General Specifications chart. 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. 7. Carry out diagnostic checks and adjustments; refer to Diagnosis By Symptom See: Powertrain Management/Transmission Control Systems/Testing Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 2680 and Inspection/Symptom Related Diagnostic Procedures/4R70E/4R75E/Diagnosis By Symptom. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity FRONT AXLE ...................................................................................................................................... ................................. 3.5 - 3.7 pints (1.8 - 2.0 liters) REAR AXLE Conventional differential ................................................................................................. ..................................................................... 4.5 pints (2.13 liters) Limited-slip differential ................. ..................................................................................................................................................... 4.25 pints (2.01 liters) NOTE: Your vehicles rear axle is filled with a synthetic rear axle lubricant and is considered lubricated for life. These lubricants are not to be checked or changed unless a leak is suspected, service is required or the axle has been submerged in water. The axle lubricant should be changed any time the axle has been submerged in water. NOTE: Add 4 oz. (118 ml) of Additive Friction Modifier XL-3 (or equivalent) for complete refill of Ford Limited Slip axles. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 2685 Fluid - Differential: Fluid Type Specifications Differential Fluid Type REAR AXLE Motorcraft SAE 75W-140 Synthetic Rear Axle Lube Ford P/N ...................................... .............................................................................................................................................................. . XY-75W140-QL Ford Specification ................................................................................................... ................................................................................... WSL-M2C192-A FRONT AXLE Motorcraft SAE 80W-90 Premium Rear Axle Lube Ford P/N ...................................... .............................................................................................................................................................. ... XY-80W90-QL Ford Specification ................................................................................................... ................................................................................... WSP-M2C197-A NOTE: Add 4.0 oz. (118 ml) of Additive Friction Modifier XL-3 or equivalent for complete refill of Ford Limited Slip rear axles. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Case Capacity ....................................................................................................................... .................................................................... 2.0 Quarts Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 2690 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Fluid Type ..................................................................................................................................................... ............................................................. Mercon ATF Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Page 2691 Fluid - Transfer Case: Service and Repair Transfer Case Draining and Filling Special Tools Materials 1. Remove the drain plug and drain the fluid. Clean the drain plug and the drain plug area. Apply thread sealant to the drain plug threads. Reinstall the drain plug. ^ To install, tighten to 15 Nm (11 ft. lbs.). 2. Clean the area around the fill plug. Remove the fill plug. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Page 2692 3. CAUTION: Incorrect fluid fill can result in transfer case failure. Using the special tool, fill the transfer case to specification. ^ The fluid must be just below the fill plug hole. Fill the case until the fluid slowly flows over the fill plug threads. Clean the fluid from the fill plug area. 4. Apply thread sealant to the fill plug threads, then install the fill plug. ^ Tighten to 15 Nm (11 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter ............................................................................................................................................ ............................................................. 6.6L (7.0 Qt) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2697 Engine Oil: Fluid Type Specifications Engine Oil U.S.A. ................................................................................................................................... Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil Canada .................................................................................................................................................. Motorcraft SAE 5W-20 Super Premium Motor Oil Ford P/N .............................................................................................................................................. ........................................... XO-5W20-QSP (U.S.A) Ford P/N ............................................................ ...................................................................................................................... CXO-5W20-LSP12 (Canada) Ford Specification ......................................................................................................................................... WSS-M2C930-A with API Certification Mark NOTE: Use of synthetic or synthetic blend motor oil is not mandatory. Engine oil need only meet the requirements of Ford specification WSS-M2C930-A and the API Certification mark. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 2702 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 2703 Power Steering Fluid: Specifications POWER STEERING FLUID Motorcraft MERCON ATF Ford P/N .............................................................................................................................................. ............................................................ XT-2-QDX Ford Specification ................................................. ............................................................................................................................................ MERCON Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Item....................................................................................................................................................... ..............................................................Specification Refrigerant and Capacity Capacity without auxiliary climate control............................................................................................. ..........................................................1.13 kg (40 oz) Capacity with auxiliary climate control............... .............................................................................................................................................1.64 kg (58 oz) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 2708 Refrigerant: Fluid Type Specifications REFRIGERANT TYPE R134a Refrigerant Ford P/N .............................................................................................................................................. ..................................................................... YN-19 Ford Specification ............................................... .................................................................................................................................... WSH-M17B19-A Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 2709 Refrigerant: Description and Operation REFRIGERANT SYSTEM DYE Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in refrigerant system leak diagnosis using a Rotunda-approved ultraviolet blacklight. It is not necessary to add additional dye to the refrigerant system before diagnosing leaks, even if a significant amount of refrigerant has been removed from the system. New suction accumulators are shipped with a fluorescent dye "wafer" included in the desiccant bag which will dissolve after approximately 30 minutes of continued A/C operation. It is not necessary to add dye after flushing or filtering the refrigerant system because a new suction accumulator is installed as part of the flushing or filtering procedure. Additional refrigerant system dye should only be added if more than 50% of the refrigerant system lubricant capacity has been lost due to a fitting separation, hose rupture or other damage. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Testing and Inspection > Fluorescent Dye Leak Detection Refrigerant: Testing and Inspection Fluorescent Dye Leak Detection FLUORESCENT DYE LEAK DETECTION Special Tool(s) Special Tool(s) Fluorescent Dye Detection NOTE: Ford Motor Company vehicles are produced with R-134a fluorescent dye installed in the refrigerant system from the factory. The location of leaks can be pinpointed by the bright yellow-green glow of the fluorescent dye under a UV lamp. Since more than one leak can exist, make sure to inspect each component, line and fitting in the refrigerant system for a leak. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Testing and Inspection > Fluorescent Dye Leak Detection > Page 2712 1. Check for leaks using a Rotunda-approved UV lamp. - Inspect all components, lines and fittings of the refrigerant system. 2. If a leak is found, recover the refrigerant. 3. Repair the refrigerant system leak(s). 4. Evacuate and charge the refrigerant system. 5. After the leak(s) is/are repaired, remove any traces of fluorescent dye with a general purpose oil solvent. 6. Verify the repair by running the vehicle for a short period of time and rechecking the area of the leak with a Rotunda-approved UV lamp. Fluorescent Dye Injection - Using an A/C Refrigerant Center and Dye Injector NOTE: - Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in refrigerant system leak diagnosis using a Rotunda-approved ultraviolet blacklight. It is not necessary to add additional dye to the refrigerant system before diagnosing leaks, even if a significant amount of refrigerant has been removed from the system. Replacement suction accumulators and receiver/driers are shipped with a fluorescent dye "wafer" included in the desiccant bag which will dissolve after approximately 30 minutes of continued A/C operation. It is not necessary to add dye after flushing or filtering the refrigerant system because a new suction accumulator or receiver/drier is installed as part of the flushing or filtering procedure. Additional refrigerant system dye should only be added if more than 50% of the refrigerant system lubricant capacity has been lost due to a fitting separation, hose rupture or other damage. - Before using the R-134a fluorescent dye injector for the first time, refer to the manufacturers instructions on evacuation of any non-condensable gasses from the hoses. - Only connect the R-134a fluorescent dye injector to a manifold and gauge set or R-134a service center when fluorescent dye is to be injected. The R-134a fluorescent dye injector has a one way check valve that will prevent refrigerant system recovery and evacuation. - Refrigerant system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the engine off. 1. Connect an R-134a A/C refrigerant service center or a manifold and gauge set to the refrigerant system service port valves. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Testing and Inspection > Fluorescent Dye Leak Detection > Page 2713 2. Verify that the valves on the fluorescent dye injector are closed. 3. Fill the fluorescent dye injector reservoir with 7 ml (0.25 oz) of fluorescent dye. 4. Install the fluorescent dye injector between the low-pressure service gauge port valve and the R-134a refrigerant service center or manifold gauge set. 5. Open all valves and inject the fluorescent dye into the refrigerant system. 6. When fluorescent dye injection is complete, close all valves. 7. Recover the refrigerant from the R-134a fluorescent dye injector. 8. Remove the fluorescent dye injector from the low-pressure service gauge port valve and the R-134a A/C refrigerant service center or manifold gauge set. Fluorescent Dye Injection - Using a Dye Injector Loop Kit NOTE: - Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in refrigerant system leak diagnosis using a Rotunda-approved ultraviolet blacklight. It is not necessary to add additional dye to the refrigerant system before diagnosing leaks, even if a significant amount of refrigerant has been removed from the system. Replacement suction accumulators and receiver/driers are shipped with a fluorescent dye "wafer" included in the desiccant bag which will dissolve after approximately 30 minutes of continued A/C operation. It is not necessary to add dye after flushing or filtering the refrigerant system because a new suction accumulator or receiver/drier is installed as part of the flushing or filtering procedure. Additional refrigerant system dye should only be added if more than 50% of the refrigerant system lubricant capacity has been lost due to a fitting separation, hose rupture or other damage. - Before using the R-134a fluorescent dye injector for the first time, refer to the equipment manufacturers instructions on evacuation of non-condensable gasses from the hoses. - Refrigerant system pressure should be between 413-551 kPa (60-80 psi) at 24°C. 1. Verify that the valves on the deluxe injector loop kit are closed. 2. Fill the deluxe injector loop kit reservoir with 7 ml (0.25 oz) of fluorescent dye. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Testing and Inspection > Fluorescent Dye Leak Detection > Page 2714 3. Install the deluxe injector loop kit between the high-pressure and low-pressure service gauge port valves. 4. CAUTION: Make sure all tools and hoses are clear of the engine cooling fan and drive belt before starting the engine. Start the engine. 5. Open the high-pressure service valve. 6. Open the deluxe injector loop kit valves and inject the fluorescent dye into the refrigerant system. 7. Close the high-pressure service valve to allow the pressure inside the deluxe injector loop kit to equalize with the suction side of the refrigerant system. 8. NOTE: Close the valves on the deluxe injector loop kit while the A/C compressor is operating. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Testing and Inspection > Fluorescent Dye Leak Detection > Page 2715 Close the valves on the deluxe injector loop kit. 9. NOTE: Leave all valves on the special tool closed when not in use. Disconnect the high-pressure and low-pressure service valves and remove the deluxe injector loop kit from the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Testing and Inspection > Fluorescent Dye Leak Detection > Page 2716 Refrigerant: Testing and Inspection Electronic Leak Detection ELECTRONIC LEAK DETECTION H10PM Refrigerant Leak Detector With Battery Special Tool(s) CAUTION: Good ventilation is necessary in the area where electronic A/C leak testing is to be carried out. If the surrounding air is contaminated with refrigerant gas, the leak detector will indicate this gas all the time. Odors from other chemicals such as antifreeze, diesel fuel, disc brake cleaner or other cleaning solvents can cause the same problem. Using a fan to ventilate the area to be tested before proceeding with the leak detection procedure is helpful in removing small traces of contamination from the air, but the fan should be turned off during actual testing. 1. NOTE: The system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the engine off. Leak test the refrigerant system using the Refrigerant Leak Detector. Follow the instructions included with the leak detector for handling and operation techniques. 2. If a leak is found, recover the refrigerant. - Repair the system. - Test the system for normal operation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant Discharging and Recovery Procedure Refrigerant: Service and Repair Refrigerant Discharging and Recovery Procedure AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING Special Tool(s) Special Tool(s) Refrigerant System Recovery NOTE: - Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation and charging may be accomplished using a separate recovery station, vacuum pump, charging meter and manifold gauge set. - Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant Discharging and Recovery Procedure > Page 2719 1. Prior to recovering, you must verify the purity of the refrigerant. 2. Connect an R-134a refrigerant service center to the low- and high-pressure service gauge port valves following the operating instructions provided by the equipment manufacturer. 3. Recover the refrigerant from the system following the operating instructions provided by the equipment manufacturer. 4. Once the refrigerant service center has recovered the refrigerant, switch OFF the power supply. 5. Allow the system to set for about 2 minutes, and observe the system vacuum reading. If the vacuum is not lost, disconnect the recovery equipment. 6. If the system does lose vacuum, repeat Steps 3 through 5 until the vacuum level remains stable for 2 minutes. 7. Carry out the required repairs. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant Discharging and Recovery Procedure > Page 2720 Refrigerant: Service and Repair Evacuation and Charging AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING Special Tool(s) Special Tool(s) Refrigerant System Evacuation Using an R-134a Service Center NOTE: - Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation and charging may be accomplished using a separate recovery station, vacuum pump, charging meter and manifold gauge set. - Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant Discharging and Recovery Procedure > Page 2721 1. Connect an R-134a service center to the low- and high-pressure service gauge port valves following the operating instructions provided by the equipment manufacturer. 2. Evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) of vacuum and as close to 101.1 kPa (30 in-Hg) as possible. Continue to operate the vacuum pump for a minimum of 45 minutes. 3. Turn off the vacuum pump. Observe the low-pressure gauge for 5 minutes to make sure that the system vacuum is held. If vacuum is not held for 5 minutes, leak test the system, repair the leak and evacuate the system again. Refrigerant System Evacuation Using an R-134a Manifold Gauge Set NOTE: - Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation and charging may be accomplished using a separate recovery station, vacuum pump, charging meter and manifold gauge set. - Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. 1. Connect the R-134a manifold gauge set to the low-side and high-side service gauge port valves. 2. Connect the center (yellow) hose from the manifold gauge set to the suction port on the vacuum pump. 3. Open all valves on the R-134a manifold gauge set and both service gauge port valves. 4. Turn on the vacuum pump and evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) of vacuum and as close to 101.1 kPa (30 in-Hg) as possible. Continue to operate the vacuum pump for a minimum of 45 minutes. 5. Close the high-side and low-side valves on the manifold gauge set (not the service gauge port valves) and turn off the vacuum pump. 6. Observe the low-pressure gauge for 5 minutes to make sure that the system vacuum is held. If vacuum is not held for 5 minutes, leak test the system, repair the leak and evacuate the system again. Refrigerant System Charging Using an R-134a Service Center NOTE: - Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation and charging may be accomplished using a separate recovery station, vacuum pump, charging meter and manifold gauge set. - Leaks in refrigerant system service equipment, hoses or gauges can cause a leak that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. 1. Lubricate the refrigerant system with the correct amount of clean PAG oil. 2. Connect an R-134a A/C service center to the low-side and high-side service gauge port valves following the operating instructions provided by the equipment manufacturer. 3. Set the refrigerant charge amount, and charge the refrigerant system following the instructions provided by the equipment manufacturer. Refrigerant System Charging NOTE: - Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation and charging may be accomplished using a separate recovery station, vacuum pump, charging meter and manifold gauge set. - Leaks in refrigerant system service equipment, hoses or gauges can cause a leak that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. 1. Lubricate the refrigerant system with the correct amount of clean PAG oil. 2. Assemble the R-134a manifold gauge set, automatic refrigerant charging meter and R-134a supply tank following the automatic refrigerant charging meter operating instructions. 3. Charge the refrigerant system following the automatic refrigerant charging meter operating instructions. 4. If the refrigerant flow stops before the refrigerant charge is complete, start the engine, select A/C operation and allow the refrigerant charge to complete. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant Discharging and Recovery Procedure > Page 2722 Refrigerant: Service and Repair Refrigerant Identification Testing REFRIGERANT IDENTIFICATION TESTING Refrigerant Identifier With Air-Radicator Special Tool(s) Refrigerant Identification 1. NOTE: An A/C refrigerant analyzer must be used to identify gas samples taken directly from the refrigeration system or storage containers prior to recovering or charging the refrigerant system. Follow the instructions included with the refrigerant identifier to obtain the sample for testing. 2. The diagnostic tool will display one of the following: - If the purity level of R-134a is 98% or greater by weight, the green "PASS" light emitting diode (LED) will light. The weight concentrations of R-134a, R-12, R-22, hydrocarbons, and air will be displayed on the digital display. - If refrigerant R-134a does not meet the 98% purity level, the red "FAIL" LED will light and an alarm will sound alerting the user of potential hazards. The weight concentrations of R-134a, R-12, R-22, and hydrocarbons will be displayed on the digital display. - If hydrocarbon concentrations are 2% or greater by weight, the red "FAIL" LED will light, "Hydrocarbon High" will be displayed on the digital display, and an alarm will sound alerting the user of potential hazards. The weight concentrations of R-134a, R-12, R-22, and hydrocarbons will also be displayed on the digital display. 3. The percentage of air contained in the sample will be displayed if the R-134a content is 98% or greater. The diagnostic tool eliminates the effect of air when determining the refrigerant sample content because air is not considered a contaminant, although air can affect A/C system performance. When the diagnostic tool has determined that a refrigerant source is pure (R-134a is 98% or greater by weight) and air concentration levels are 2% or greater by weight, the diagnostic tool will prompt the user if an air purge is desired. 4. If contaminated refrigerant is detected, repeat the refrigerant identification test to verify that the refrigerant is indeed contaminated. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant Discharging and Recovery Procedure > Page 2723 Refrigerant: Service and Repair Contaminated Refrigerant Handling CONTAMINATED REFRIGERANT HANDLING CAUTION: If contaminated refrigerant is detected, DO NOT recover the refrigerant into R-134a recovery/recycling equipment. NOTE: A new suction accumulator or receiver/drier must be installed as directed by the air conditioning system flushing procedure. 1. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant only. - If this equipment is not available, contact an A/C service facility in your area with the correct equipment to carry out this service. 2. Determine and correct the cause of the customers initial concern. 3. Flush the air conditioning system. 4. Dispose of the contaminated refrigerant in accordance with all federal, state and local regulations. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications REFRIGERANT OIL TOTAL SYSTEM CAPACITY Without auxiliary climate control ............................................................................................................................................................ 266 ml (9.0 oz) With auxiliary climate control ...................................................................................... ......................................................................... 414 ml (14.0 oz) A/C COMPRESSOR Add the same amount drained plus the amount collected during refrigerant recovery. NOTE: Rotate the old A/C compressor shaft 8 to 10 full rotations (clockwise) while collecting the refrigerant oil in a clean measuring cup. Service A/C compressors are shipped without refrigerant oil. SUCTION ACCUMULATOR OR RECEIVER/DRIER Add the quantity of oil drained, plus the amount collected during refrigerant recovery and 60 ml (2.0 fl oz). NOTE: Drill one 12.7 mm (1/2 inch) hole in the old suction accumulator or receiver/drier cylinder and drain the oil into a clean measuring cup. EVAPORATOR CORE ........................................................................................................................ ................................................ 45 ml (1.5 fl oz.) NOTE: Added to the amount collected during refrigerant recovery. CONDENSER CORE .......................................................................................................................... ................................................. 60 ml (2.0 fl oz.) NOTE: Added to the amount collected during refrigerant recovery. EVAPORATOR CORE ORIFICE OR THERMOSTATIC EXPANSION VALVE The amount collected during refrigerant recovery. A/C PRESSURE RELIEF VALVE ...................................................................................................................................................... 60 ml (2.0 fl oz.) REFRIGERANT HOSE/LINE ............................................................................................................................................................. 60 ml (2.0 fl oz.) NOTE: If an excessive amount of refrigerant oil is lost due to a hose rupture/separation or other damage, the total system refrigerant oil capacity must be added. O-RING LEAK REPAIR ....................................................................................................................... .............................................. 60 ml (2.0 fl oz.) NOTE: The amount specified may be used for one or multiple O-ring leak repairs. Do not multiply the refrigerant oil amount by the number of O-ring leaks being repaired. SERVICE PORT LEAK REPAIR ....................................................................................................................................................... 60 ml (2.0 fl oz.) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 2728 Refrigerant Oil: Fluid Type Specifications REFRIGERANT OIL PAG Refrigerant Compressor Oil (R-134a Systems) Ford P/N .............................................................................................................................................. .................................................. F7AZ-19589-DA Motorcraft P/N ....................................................... ............................................................................................................................................. YN-12-C Ford Specification ................................................................................................................................ .................................................. WSH-M1C231-B Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 2729 Refrigerant Oil: Service and Repair REFRIGERANT OIL ADDING Special Tool(s) Special Tool(s) CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant, and a small amount is retained in each component. If certain components of the system are removed, some of the refrigerant oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part. Part 1 Part 2 1. Refer to the chart for refrigerant oil adding amounts and methods of installation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 2730 Refrigerant Oil Adding for New A/C Compressor Installation NOTE: Service A/C compressors are shipped without refrigerant oil. 1. Rotate the old A/C compressor shaft 8 to 10 full rotations (clockwise) while collecting the refrigerant oil in a clean measuring cup. - Add the same amount plus the amount collected during refrigerant recovery. Refrigerant Oil Adding for New Suction Accumulator or Receiver/Drier Installation 1. Drill one half-inch hole in the old suction accumulator or receiver/drier cylinder and drain the oil into a clean measuring cup. 2. Add the quantity of oil drained, plus the amount collected during refrigerant recovery and 60 ml (2 oz.). Oil Injection Using a Dye/Lubricant Injector NOTE: If fluorescent leak detection dye is also to be added during A/C charging, the dye may be added to the dye/lubricant injector along with the refrigerant oil. 1. Evacuate the refrigerant system. 2. Assemble the dye/lubricant injector using the correct adapters to match the amount of PAG oil to be injected. 3. Verify that all the valves on the dye/lubricant injector are closed. 4. Fill the dye/lubricant injector with the correct amount of clean PAG oil. 5. Install the dye/lubricant injector between the low-side service gauge port valve and the refrigerant service station or manifold gauge set. 6. Open all valves and charge the refrigerant system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > Customer Interest for Brake Bleeding: > 05-26-21 > Dec > 05 > Brakes - Unintended Brake Assist Brake Bleeding: Customer Interest Brakes - Unintended Brake Assist TSB 05-26-21 12/31/05 UNINTENDED BRAKE ASSIST FORD: 2003-2006 Expedition LINCOLN: 2003-2006 Navigator ISSUE Some 2003-2006 Expedition/Navigator may exhibit excessive pedal travel and/or low pedal effort, due to the mechanical or electronic brake assist being activated. ACTION Review the brake assist characteristics and follow the Service Procedure if required. Brake Assist Characteristics: The booster gain will be increased during panic braking, which increases brake pressure and reduces pedal forces. The brakes will go to maximum pressure and the tires will chirp, sounding as if the tires are locking up (normal anti-lock brake control should be present). The pedal efforts will drop dramatically since the booster is providing maximum boost, which allows the pedal to travel with little effort; this is normal. It feels as if the pedal travels excessively, but the system is generating maximum brake pressure when this occurs; again, this is normal. When statically applying the brake pedal very hard, you may hear or feel (in the pedal) a slight click. This is the brake assist feature engaging inside the booster. The system will remain active as long as the brake pedal is depressed. NOTE MECHANICAL BRAKE ASSIST BOOSTERS ARE USED ON VEHICLES NOT EQUIPPED WITH RIDE STABILITY CONTROL. Vehicles equipped with Ride Stability Control receive an electronic active booster, which provides the brake assist feature by activating an electronic solenoid inside the booster. The active booster will provide similar pedal feedback when the feature is engaged, but the subtle clicks will not be present. SERVICE PROCEDURE To service, first advise the customer that the feature is there to help assist during panic braking. If the customer did not experience a panic braking situation, then the brake assist may have been unintended, on a mechanical brake assist system. Check for conditions that would lower the brake pedal height and activate the brake assist. 1. Check for air in the brake lines, repair any leaks and bleed the brake lines as necessary. Refer to the Workshop Manual, Section 206-00 General Procedures. 2. Inspect the brake linings for excessive wear, which can increase the pedal travel and engage the mechanical brake assist. Refer to the Workshop Manual, Section 206-00 Diagnosis and Testing. 3. Check the vacuum line between the booster and the manifold for obstructions or kinks. Repair as necessary. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2001 30 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > 05-26-21 > Dec > 05 > Brakes - Unintended Brake Assist Brake Bleeding: All Technical Service Bulletins Brakes - Unintended Brake Assist TSB 05-26-21 12/31/05 UNINTENDED BRAKE ASSIST FORD: 2003-2006 Expedition LINCOLN: 2003-2006 Navigator ISSUE Some 2003-2006 Expedition/Navigator may exhibit excessive pedal travel and/or low pedal effort, due to the mechanical or electronic brake assist being activated. ACTION Review the brake assist characteristics and follow the Service Procedure if required. Brake Assist Characteristics: The booster gain will be increased during panic braking, which increases brake pressure and reduces pedal forces. The brakes will go to maximum pressure and the tires will chirp, sounding as if the tires are locking up (normal anti-lock brake control should be present). The pedal efforts will drop dramatically since the booster is providing maximum boost, which allows the pedal to travel with little effort; this is normal. It feels as if the pedal travels excessively, but the system is generating maximum brake pressure when this occurs; again, this is normal. When statically applying the brake pedal very hard, you may hear or feel (in the pedal) a slight click. This is the brake assist feature engaging inside the booster. The system will remain active as long as the brake pedal is depressed. NOTE MECHANICAL BRAKE ASSIST BOOSTERS ARE USED ON VEHICLES NOT EQUIPPED WITH RIDE STABILITY CONTROL. Vehicles equipped with Ride Stability Control receive an electronic active booster, which provides the brake assist feature by activating an electronic solenoid inside the booster. The active booster will provide similar pedal feedback when the feature is engaged, but the subtle clicks will not be present. SERVICE PROCEDURE To service, first advise the customer that the feature is there to help assist during panic braking. If the customer did not experience a panic braking situation, then the brake assist may have been unintended, on a mechanical brake assist system. Check for conditions that would lower the brake pedal height and activate the brake assist. 1. Check for air in the brake lines, repair any leaks and bleed the brake lines as necessary. Refer to the Workshop Manual, Section 206-00 General Procedures. 2. Inspect the brake linings for excessive wear, which can increase the pedal travel and engage the mechanical brake assist. Refer to the Workshop Manual, Section 206-00 Diagnosis and Testing. 3. Check the vacuum line between the booster and the manifold for obstructions or kinks. Repair as necessary. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2001 30 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 2744 Brake Bleeding: By Symptom Technical Service Bulletin # 05-26-21 Date: 051231 Brakes - Unintended Brake Assist TSB 05-26-21 12/31/05 UNINTENDED BRAKE ASSIST FORD: 2003-2006 Expedition LINCOLN: 2003-2006 Navigator ISSUE Some 2003-2006 Expedition/Navigator may exhibit excessive pedal travel and/or low pedal effort, due to the mechanical or electronic brake assist being activated. ACTION Review the brake assist characteristics and follow the Service Procedure if required. Brake Assist Characteristics: The booster gain will be increased during panic braking, which increases brake pressure and reduces pedal forces. The brakes will go to maximum pressure and the tires will chirp, sounding as if the tires are locking up (normal anti-lock brake control should be present). The pedal efforts will drop dramatically since the booster is providing maximum boost, which allows the pedal to travel with little effort; this is normal. It feels as if the pedal travels excessively, but the system is generating maximum brake pressure when this occurs; again, this is normal. When statically applying the brake pedal very hard, you may hear or feel (in the pedal) a slight click. This is the brake assist feature engaging inside the booster. The system will remain active as long as the brake pedal is depressed. NOTE MECHANICAL BRAKE ASSIST BOOSTERS ARE USED ON VEHICLES NOT EQUIPPED WITH RIDE STABILITY CONTROL. Vehicles equipped with Ride Stability Control receive an electronic active booster, which provides the brake assist feature by activating an electronic solenoid inside the booster. The active booster will provide similar pedal feedback when the feature is engaged, but the subtle clicks will not be present. SERVICE PROCEDURE To service, first advise the customer that the feature is there to help assist during panic braking. If the customer did not experience a panic braking situation, then the brake assist may have been unintended, on a mechanical brake assist system. Check for conditions that would lower the brake pedal height and activate the brake assist. 1. Check for air in the brake lines, repair any leaks and bleed the brake lines as necessary. Refer to the Workshop Manual, Section 206-00 General Procedures. 2. Inspect the brake linings for excessive wear, which can increase the pedal travel and engage the mechanical brake assist. Refer to the Workshop Manual, Section 206-00 Diagnosis and Testing. 3. Check the vacuum line between the booster and the manifold for obstructions or kinks. Repair as necessary. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2001 30 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 2745 Disclaimer Technical Service Bulletin # 05-26-21 Date: 051231 Brakes - Unintended Brake Assist TSB 05-26-21 12/31/05 UNINTENDED BRAKE ASSIST FORD: 2003-2006 Expedition LINCOLN: 2003-2006 Navigator ISSUE Some 2003-2006 Expedition/Navigator may exhibit excessive pedal travel and/or low pedal effort, due to the mechanical or electronic brake assist being activated. ACTION Review the brake assist characteristics and follow the Service Procedure if required. Brake Assist Characteristics: The booster gain will be increased during panic braking, which increases brake pressure and reduces pedal forces. The brakes will go to maximum pressure and the tires will chirp, sounding as if the tires are locking up (normal anti-lock brake control should be present). The pedal efforts will drop dramatically since the booster is providing maximum boost, which allows the pedal to travel with little effort; this is normal. It feels as if the pedal travels excessively, but the system is generating maximum brake pressure when this occurs; again, this is normal. When statically applying the brake pedal very hard, you may hear or feel (in the pedal) a slight click. This is the brake assist feature engaging inside the booster. The system will remain active as long as the brake pedal is depressed. NOTE MECHANICAL BRAKE ASSIST BOOSTERS ARE USED ON VEHICLES NOT EQUIPPED WITH RIDE STABILITY CONTROL. Vehicles equipped with Ride Stability Control receive an electronic active booster, which provides the brake assist feature by activating an electronic solenoid inside the booster. The active booster will provide similar pedal feedback when the feature is engaged, but the subtle clicks will not be present. SERVICE PROCEDURE To service, first advise the customer that the feature is there to help assist during panic braking. If the customer did not experience a panic braking situation, then the brake assist may have been unintended, on a mechanical brake assist system. Check for conditions that would lower the brake pedal height and activate the brake assist. 1. Check for air in the brake lines, repair any leaks and bleed the brake lines as necessary. Refer to the Workshop Manual, Section 206-00 General Procedures. 2. Inspect the brake linings for excessive wear, which can increase the pedal travel and engage the mechanical brake assist. Refer to the Workshop Manual, Section 206-00 Diagnosis and Testing. 3. Check the vacuum line between the booster and the manifold for obstructions or kinks. Repair as necessary. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2001 30 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 2746 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) Brake Bleeding: Service and Repair Four Wheel Anti-Lock Brake System (4WABS) Four Wheel Anti-Lock Brake System (4WABS) WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse 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 diagnostic 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 bleeding removes 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 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. ^ Tighten to 16 Nm (12 ft. lbs.). 5. Repeat Steps 1 through 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. ^ Tighten to 16 Nm (12 ft. lbs.). 6. NOTE: Go to the Help menu in the diagnostic tool. Connect the diagnostic tool DCL cable adapter into the vehicle data link connector (DLC) under the dash and follow the diagnostic tool instructions. 7. Repeat the conventional bleed procedure as outlined in Steps 1 through 5. 8. If the brake pedal feels spongy, repeat the diagnostic tool service bleed procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 2749 Brake Bleeding: Service and Repair Gravity Gravity WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse 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: 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 brake fluid. 2. Bleed the rear disc brake calipers. ^ 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. ^ 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. ^ Tighten to 16 Nm (12 ft. lbs.). 4. Bleed the front disc brake calipers. ^ 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 clean brake fluid. ^ 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. ^ Tighten to 16 Nm (12 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 2750 Brake Bleeding: Service and Repair Manual Manual WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse 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. ^ Tighten to 16 Nm (12 ft. lbs.). 5. Repeat Steps 1 through 4 for the LH rear disc brake caliper. 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 clean 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. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 2751 9. Tighten the RH front disc brake caliper bleeder screw. ^ Tighten to 16 Nm (12 ft. lbs.). 10. Repeat Steps 6 through 9 for the LH front disc brake caliper bleeder screw. 11. If necessary, bleed the brake master cylinder. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 2752 Brake Bleeding: Service and Repair Pressure Pressure WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. ^ WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse 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 operation. 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. 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. ^ Tighten to 16 Nm (12 ft. lbs.). 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. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 2753 8. Fill the brake master cylinder reservoir and install the brake master cylinder filler cap. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 2754 Brake Bleeding: Service and Repair Four Wheel Anti-Lock Brake System (4WABS) Four Wheel Anti-Lock Brake System (4WABS) WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse 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 diagnostic 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 bleeding removes 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 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. ^ Tighten to 16 Nm (12 ft. lbs.). 5. Repeat Steps 1 through 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. ^ Tighten to 16 Nm (12 ft. lbs.). 6. NOTE: Go to the Help menu in the diagnostic tool. Connect the diagnostic tool DCL cable adapter into the vehicle data link connector (DLC) under the dash and follow the diagnostic tool instructions. 7. Repeat the conventional bleed procedure as outlined in Steps 1 through 5. 8. If the brake pedal feels spongy, repeat the diagnostic tool service bleed procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 2755 Gravity Gravity WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse 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: 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 brake fluid. 2. Bleed the rear disc brake calipers. ^ 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. ^ 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. ^ Tighten to 16 Nm (12 ft. lbs.). 4. Bleed the front disc brake calipers. ^ 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 clean brake fluid. ^ 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. ^ Tighten to 16 Nm (12 ft. lbs.). Manual Manual WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 2756 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. ^ Tighten to 16 Nm (12 ft. lbs.). 5. Repeat Steps 1 through 4 for the LH rear disc brake caliper. 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 clean 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. ^ Tighten to 16 Nm (12 ft. lbs.). 10. Repeat Steps 6 through 9 for the LH front disc brake caliper bleeder screw. 11. If necessary, bleed the brake master cylinder. Pressure Pressure WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. ^ WARNING: 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. Failure to follow these instructions may result in personal injury. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 2757 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 operation. 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. 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. ^ Tighten to 16 Nm (12 ft. lbs.). 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. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 2758 8. Fill the brake master cylinder reservoir and install the brake master cylinder filler cap. Brake System Bleeding Brake System Bleeding Special Tool(s) Material WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse 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. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 2759 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 brake fluid. 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. 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. ^ Tighten to 25 Nm (18 ft. lbs.). Master Cylinder, Bench Master Cylinder, Bench WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse 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. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 2760 1. Support the brake master cylinder body in a vise and fill the brake master cylinder reservoir with specified brake fluid. ^ Use clean brake fluid. 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. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Depowering and Repowering SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING Depowering Procedure WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the electrical connector on a safety canopy module. Doing so can result in safety canopy deployment. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the RH side of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse 19 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located at the bottom of the hood latch support bracket. The first row side impact sensors (if equipped) are located in the first row doors, behind the door trim panel. The second row side impact sensors (if equipped) are located at or near the base of the C-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install the RCM fuse 19 (10A) to the CJB and close the cover. 4. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2765 Connect the battery ground cable. 5. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a diagnostic tool. Deactivation and Reactivation SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION Special Tool(s) Special Tool(s) Deactivation WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the connectors on the safety canopy module. Doing so can result in safety canopy module deployment. - To reduce the risk of personal injury, do not use any memory saver devices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2766 NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the RH side of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse 19 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located at the bottom of the hood latch support bracket. The first row side impact sensors (if equipped) are located in the first row doors, behind the door trim panel. The second row side impact sensors (if equipped) are located at or near the base of the C-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 7. Remove the 2 steering wheel back cover plugs (1 shown). 8. Remove the 2 driver air bag module bolts (1 shown). Expedition Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2767 9. Remove the driver air bag module. 1 Release the 2 retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector before disconnecting. 2 Release the 2 retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector before disconnecting. 3 Disconnect the horn switch electrical connector. 4 Remove the driver air bag module. Navigator 10. Disconnect the driver air bag module. - Release the 2 tabs on each driver air bag module electrical connector and disconnect them. Label each driver air bag module electrical connector before disconnecting. 11. Release the tab and disconnect the driver air bag module accessories electrical connector at the top of the clockspring and remove the driver air bag module. All vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2768 12. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of the steering column. 13. While pushing in on the 2 glove compartment door tabs, position the glove compartment downward. 14. NOTE: Expedition shown, Navigator similar. Through the glove compartment opening, release the tab and disconnect the passenger air bag module electrical connector. 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Vehicles with safety canopies Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2769 16. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or if it does not remain closed, install a new shoulder safety belt guide cover. Remove the second row passenger side safety belt guide. 1 Release the retaining tab at each side and open the safety belt guide cover. 2 Remove the nut. 3 Remove the second row passenger side safety belt guide. 17. Remove the passenger side C-pillar trim panel. 1 Separate the weather-stripping along the passenger side C-pillar trim panel. 2 Remove the bolt cover and bolt. 3 Pull out to release the retainers and remove the passenger side C-pillar trim panel. 18. Disconnect the passenger side safety canopy electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2770 19. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy electrical connector. 20. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or if it does not remain closed, install a new shoulder safety belt guide cover. Remove the second row driver side safety belt guide. 1 Release the retaining tab at each side and open the safety belt guide cover. 2 Remove the nut. 3 Remove the second row driver side safety belt guide. 21. Remove the driver side C-pillar trim panel. 1 Separate the weather-stripping along the driver side C-pillar trim panel. 2 Remove the bolt cover and bolt. 3 Pull out to release the retainers and remove the driver side C-pillar trim panel. 22. Disconnect the driver side safety canopy electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2771 23. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy electrical connector. All vehicles 24. Install the RCM fuse 19 (10A) to the CJB. 25. Connect the battery ground cable. Reactivation All vehicles 1. Remove the RCM fuse 19 (10A) from the CJB. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles with safety canopies 3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy electrical connector. 4. Connect the driver side safety canopy electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2772 5. WARNING: Anytime the safety canopy module has deployed, the headliner, and all A, B, and C pillar upper trim panels and attaching hardware must be replaced along with any other damaged components and hardware. Failure to do so may result in personal injury in the event of a safety canopy module deployment. Install the driver side C-pillar trim panel. 1 Position the driver side C-pillar trim panel and push in, engaging the retainers. 2 Install the bolt and bolt cover. Tighten to 11 Nm (8 lb-ft). 3 Install the weather-stripping along the driver side C-pillar trim panel. 6. NOTE: - Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or if it does not remain closed, install a new shoulder safety belt guide cover. - Make sure the safety belt is not twisted prior to installation. Install the second row driver side safety belt guide. 1 Position the second row driver side safety belt guide. 2 Install the nut. Tighten to 40 Nm (30 lb-ft). 3 Close the safety belt guide cover. Verify the safety belt retractor operates without excessive effort or binding. 7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2773 8. Connect the passenger side safety canopy electrical connector. 9. WARNING: Anytime the safety canopy module has deployed, the headliner, and all A, B, and C pillar upper trim panels and attaching hardware must be replaced along with any other damaged components and hardware. Failure to do so may result in personal injury in the event of a safety canopy module deployment. Install the passenger C-pillar trim panel. 1 Position the passenger side C-pillar trim panel and push in, engaging the retainers. 2 Install the bolt and bolt cover. Tighten to 11 Nm (8 lb-ft). 3 Install the weather-stripping along the passenger side C-pillar trim panel. 10. NOTE: - Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or if it does not remain closed, install a new shoulder safety belt guide cover. - Make sure the safety belt is not twisted prior to installation. Install the second row passenger side safety belt guide. 1 Position the second row passenger side safety belt guide. 2 Install the nut. Tighten to 40 Nm (30 lb-ft). 3 Close the safety belt guide cover. Verify the safety belt retractor operates without excessive effort or binding. All vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2774 11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. 12. NOTE: Expedition shown, Navigator similar. Connect the passenger air bag module electrical connector. 13. Close the glove compartment. 14. Remove the restraint system diagnostic tools from the clockspring electrical connector at the top of the steering column. Navigator 15. Connect the driver air bag module accessories electrical connector to the connector end at the top of the clockspring. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2775 16. CAUTION: The clockspring electrical connectors are unique and cannot be reversed when connected to the driver air bag module. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Connect the driver air bag module electrical connectors as noted during removal. Position the driver air bag module to the steering wheel. Expedition 17. Position the driver air bag module to the steering wheel. 1 Connect the horn switch electrical connector. 2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when connected to the driver air bag module. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Connect the driver air bag module electrical connectors as noted during removal. 3 Position the driver air bag module to the steering wheel. All vehicles 18. Install the 2 driver air bag module bolts (1 shown). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2776 19. Install the 2 steering wheel back cover plugs (1 shown). 20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse 19 (10A) to the CJB and close the cover. 23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a diagnostic tool. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2777 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure PROVE OUT PROCEDURE Turn the ignition switch from the OFF to the ON position and visually monitor the air bag indicator with all SRS components connected or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an SRS fault is present, the air bag indicator will: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Central Junction Box Fuse: Locations Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Central Junction Box > Page 2783 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Central Junction Box > Page 2784 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Central Junction Box > Page 2785 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Central Junction Box > Page 2786 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Central Junction Box > Page 2787 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Central Junction Box > Page 2788 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Central Junction Box > Page 2789 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Central Junction Box > Page 2790 Fuse: Locations Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Central Junction Box > Page 2791 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Central Junction Box > Page 2792 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Central Junction Box > Page 2793 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Central Junction Box > Page 2794 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Central Junction Box > Page 2795 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2798 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2799 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2800 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2801 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2802 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2803 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2804 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2805 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2806 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2807 Fuse: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2808 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2809 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2810 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2811 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2812 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2813 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2814 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Central Junction Box Fuse: Application and ID Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Central Junction Box > Page 2817 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Central Junction Box > Page 2818 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Central Junction Box > Page 2819 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Central Junction Box > Page 2820 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Central Junction Box > Page 2821 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Central Junction Box > Page 2822 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Central Junction Box > Page 2823 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Central Junction Box > Page 2824 Fuse: Application and ID Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Central Junction Box > Page 2825 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Central Junction Box > Page 2826 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Central Junction Box > Page 2827 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Central Junction Box > Page 2828 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Central Junction Box > Page 2829 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Central Junction Box Fuse Block: Locations Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Central Junction Box > Page 2834 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Central Junction Box > Page 2835 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Central Junction Box > Page 2836 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Central Junction Box > Page 2837 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Central Junction Box > Page 2838 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Central Junction Box > Page 2839 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Central Junction Box > Page 2840 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Central Junction Box > Page 2841 Fuse Block: Locations Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Central Junction Box > Page 2842 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Central Junction Box > Page 2843 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Central Junction Box > Page 2844 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Central Junction Box > Page 2845 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Central Junction Box > Page 2846 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2849 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2850 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2851 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2852 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2853 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2854 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2855 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2856 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2857 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2858 Fuse Block: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2859 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2860 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2861 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2862 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2863 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2864 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2865 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2866 Fuse Block: Connector Views C270a C270b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2867 C270c C270d Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2868 C270e Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2869 C270f C270g Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2870 C270h C270j Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2871 C270k C270m Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2872 C270n C270p Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Central Junction Box Fuse Block: Application and ID Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 2875 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 2876 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 2877 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 2878 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 2879 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 2880 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 2881 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 2882 Fuse Block: Application and ID Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 2883 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 2884 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 2885 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 2886 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 2887 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Central Junction Box Relay Box: Locations Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Central Junction Box > Page 2892 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Central Junction Box > Page 2893 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Central Junction Box > Page 2894 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Central Junction Box > Page 2895 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Central Junction Box > Page 2896 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Central Junction Box > Page 2897 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Central Junction Box > Page 2898 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Central Junction Box > Page 2899 Relay Box: Locations Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Central Junction Box > Page 2900 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Central Junction Box > Page 2901 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Central Junction Box > Page 2902 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Central Junction Box > Page 2903 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Central Junction Box > Page 2904 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 2905 Relay Box: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 2906 C270a Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 2907 C270b C270c Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 2908 C270d Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 2909 C270e Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 2910 C270f C270g Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 2911 C270h C270j Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 2912 C270k C270m Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 2913 C270n C270p Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Central Junction Box Relay Box: Application and ID Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Central Junction Box > Page 2916 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Central Junction Box > Page 2917 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Central Junction Box > Page 2918 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Central Junction Box > Page 2919 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Central Junction Box > Page 2920 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Central Junction Box > Page 2921 Relay Box: Application and ID Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Central Junction Box > Page 2922 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Central Junction Box > Page 2923 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Central Junction Box > Page 2924 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Central Junction Box > Page 2925 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Central Junction Box > Page 2926 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Central Junction Box > Page 2927 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Central Junction Box > Page 2928 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Description and Operation Low Tire Pressure Indicator: Description and Operation UNDERSTANDING YOUR TIRE PRESSURE MONITORING SYSTEM (TPMS) The Tire Pressure Monitoring System measures pressure in your four road tires and sends the tire pressure readings to your vehicle every minute while you are driving and once every 6 hours when your vehicle is parked. The Low Tire Warning Lamp will turn ON if the tire pressure is 25% below the pressure listed on the Safety Compliance Certification Label (approximately 6 to 9 psi below the manufacturers recommend tire pressure). If the tire pressure increases 2 psi above the Light ON threshold, then the TPMS light will turn OFF. Once the light is illuminated, your tires are under inflated and need to be inflated to the manufacturers recommended tire pressure. Even if the light turns ON and a short time later turns OFF, your tire pressure still needs to be checked. In short, once the light has turned ON, at least one tire may be under inflated. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Description and Operation > Page 2933 Low Tire Pressure Indicator: Testing and Inspection TPM's Indicator and Vehicle Message Center Messages The TPM's indicator and vehicle message center (if equipped) sometimes displays faults that cannot be resolved by the customer. Treat these messages as TPM's faults that must be serviced. GO to Symptom Chart for the TPM's indicator operation and message center messages. See: Wheels and Tires/Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures CAUTION: Place the air chuck straight on the valve stem to inflate the tire. Do not cock the air chuck during the inflation cycle. Doing so can damage the valve stem and cause air leaks. CAUTION: Ford recommends using a round head air chuck on tire pressure sensors; it is not recommended to use air chucks with long shanks. Doing so can cause tire pressure sensor valve stem damage and loss of tire pressure. TPM's Indicator Illuminates Continuously The TPM's indicator remains on continuously for the following condition: 1. NOTE: If the spare tire is in use, the damaged road tire must be repaired and installed on the vehicle to restore complete TPM's functionality before carrying out any diagnosis. Low Tire Pressure - The TPM's indicator is illuminated solid and the message center displays LOW TIRE PRESSURE (if equipped). This is displayed when any of the tire pressures are low. Tire pressure must be adjusted to the recommended cold placard pressure. Adjust the air pressure in tires. Refer to Information BUS for diagnosis of the CAN bus. The TPM's indicator flashes for 20 seconds after prove-out and for the following 3 reasons: 1 No communication with the TPM's Module (integral to VSM) - The TPM's indicator is illuminated when the instrument cluster (IC) has received no signals from the VSM for more than 5 seconds. If equipped, the message center displays TIRE PRESSURE MONITOR FAULT. GO to Symptom Chart. See: Wheels and Tires/Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures 2 Tire Pressure Sensor Fault - If equipped, the message center will display TIRE PRESSURE SENSOR FAULT when a tire pressure sensor is malfunctioning. GO to Symptom Chart. See: Wheels and Tires/Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures 3 Tire Pressure Monitor Fault - If equipped, the message center will display TIRE PRESSURE MONITOR FAULT when the tire pressure monitoring system is malfunctioning. GO to Symptom Chart. See: Wheels and Tires/Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair Maintenance Required Lamp/Indicator: Service and Repair This vehicle is not equipped with a maintenance required lamp/indicator. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) MIL (applications With A Dedicated Hard Wire MIL Circuit) CHECK ENGINE, SERVICE ENGINE SOON, Or ISO Standard Engine Symbol The MIL notifies the driver that the powertrain control module (PCM) has detected an on board diagnostic (OBD) emission-related component or system concern. When this occurs, an OBD diagnostic trouble code (DTC) sets. - The MIL is located in the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE SOON or the international standards organization (ISO) standard engine symbol. - The MIL is illuminated during the instrument cluster prove out for approximately 4 seconds. - For applications with a dedicated hard wire MIL circuit, the PCM illuminates the MIL until a profile ignition pickup (PIP) signal is detected. The Ranger uses a hard wire circuit. - The MIL remains illuminated after instrument cluster prove out if: an emission-related concern and DTC exists. - no PIP signal is detected (applications with a dedicated hard wire MIL circuit). The PIP signal is generated in the PCM using the crankshaft position (CKP) sensor. For these applications, the MIL can be helpful in diagnosing a no start. - the PCM does not send a control message to the instrument cluster (applications with the MIL controlled through the communication link). - the PCM is operating in the Hardware Limited Operation Strategy (HLOS). - the MIL circuit is shorted to ground (applications with a dedicated hard wire MIL circuit). - The MIL remains off during the instrument cluster prove out if: an indicator or instrument cluster concern is present. - the MIL circuit is open (applications with a dedicated hard wire MIL circuit). - To turn off the MIL after a repair, a reset command from the diagnostic tool must be sent, or 3 consecutive drive cycles must be completed without a concern. - For all MIL concerns, go to Symptom Charts. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures - If the MIL flashes at a steady rate, a severe misfire condition may exist. - If the MIL flashes erratically, the PCM can reset while cranking if the battery voltage is low. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair This vehicle is not equipped with an oil change reminder lamp. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation 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 LH rear quarter trim 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. - 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 carrying out any procedure requiring the vehicle to be jacked off the ground. - Make sure the jack and jack stands are correctly 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. - If equipped with retractable running board, disable the system through the instrument cluster controls. Jacking Points - Front Jacking Points - Front The front jacking point is indicated by an arrow cutout in the frame, located behind the front tire and wheel assembly. Jacking Points - Rear Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 2947 Jacking Points - Rear CAUTION: Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and adjoining differential housing surface can occur if a floor jack or any lifting device is allowed to contact the cover at any point where the cover joins the housing. - Do not use the rear control arms as a lifting point. The rear jacking point is indicated by an arrow cutout in the frame, located in front of the rear tire and wheel assembly. LIFTING 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 LH rear quarter trim 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: Damage to suspension, exhaust and steering linkage components can occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Lifting Points - Twin Post Hoist Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 2948 Lifting Points - Twin Post Hoist Locate the front hoist adapters and rear hoist adapters (top of frame arc) as indicated. Lifting Points - Drive On Hoist Lifting Points - Drive On Hoist The vehicle is supported by tires and suspension components. Lifting Points - Floor Jack, Front Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 2949 Lifting Points - Floor Jack, Front The front can be lifted using a floor jack under the front control arm directly below the shock. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Service and Repair Tire Pressure Module: Service and Repair Tire Pressure Monitoring System Module Removal and Installation CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: The tire pressure monitoring system (TPM's) is integral to the vehicle security module (VSM) and is not serviced separately. NOTE: A new VSM module is delivered in manufacturing mode with pre-set diagnostic trouble codes (DTC's). These DTC's require that a particular set of operations to be carried out in order to clear them and enable the module for normal operations. The pre-set DTC's are as follows: ^ B2477 - Module Configuration Failure/Mismatch ^ B2868 - Left Front Tire Pressure Sensor Fault ^ B2869 - Right Front Tire Pressure Sensor Fault ^ B2870 - Left Rear Tire Pressure Sensor Fault ^ B2871 - Right Rear Tire Pressure Sensor Fault ^ C2780 - ECU in Manufacturing Mode NOTE: A re-configured VSM may also set the above codes and will need to go through the same set of procedures as a new module to enable normal operation. 1. NOTE: The steps included in the VSM removal and installation process are critical to restoring vehicle security and tire pressure monitoring system operations and will permit a new or reconfigured module to operate as intended. Each step is designed to carry out a particular operation and clear the manufacturing mode DTC's. Once these DTC's are cleared, the new or reconfigured module will enter into normal operating mode. Remove the VSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection Tire Pressure Sensor: Testing and Inspection Sensor Training (Reset Procedure) NOTE: The tire pressure monitoring system is not affected by wheel and tire rotation. NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area without radio frequency (RF) noise. RF noise is generated by electrical motor and appliance operation, cellular telephones and remote transmitters, power inverters and portable entertainment equipment. 1. Turn the ignition switch to the OFF position. 2. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. Do not wait more than 1 minute between each key cycle. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. Do not wait more than 1 minute between each key cycle. 6. The horn will sound once and the TPMS indicator will flash if train mode has been entered successfully. If equipped, the message center displays "TRAIN LF TIRE", place the special tool on the valve stem of the LF tire pressure sensor. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the TPMS module. 7. Within 2 minutes after the horn sounds, place the special tool on the valve stem of the RF tire pressure sensor. NOTE: If the VSM (TPMS module integral to VSM) does not recognize any 1 of the 4 tire pressure sensors during the tire training procedure, the horn will sound twice and the message center (if equipped) will display "TIRE NOT TRAINED REPEAT" and the procedure must be repeated. 8. Repeat Step 7 for the RR and LR tires. When the tire training procedure is complete, the horn will sound once and the message center (if equipped) will display "TIRE TRAINING MODE COMPLETE". Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 2958 Tire Pressure Sensor: Service and Repair Tire Pressure Sensor Special Tools CAUTION: Use only special tool 204-354 anytime tire pressures are measured to be sure that accurate values are obtained. CAUTION: Place the air chuck straight on the valve stem to inflate the tire. Do not cock the air chuck during the inflation cycle. Doing so can damage the valve stem and cause air leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 2959 CAUTION: Ford recommends using a round head air chuck on tire pressure sensors; it is not recommended to use air chucks with long shanks. Doing so can cause tire pressure sensor valve stem damage and loss of tire pressure. Removal NOTE: The vehicle is equipped with a light blue-colored tire pressure sensor. When installing new components, use only this tire pressure sensor. The tire pressure monitoring system (TPM's) will not operate correctly if black-colored tire pressure sensors are installed. 1. Remove the wheel and tire assembly. 2. CAUTION: Do not remove the valve stem core to relieve the tire pressure. CAUTION: If the valve stem core has been removed from the valve stem, reinstall the original valve stem core. If the original valve stem core is damaged, a nickel-plated core must be installed. Failure to use a nickel-plated core will result in corrosion and the possible loss of tire pressure. NOTE: Release the tire pressure by removing the sensor valve stem nut. With the valve stem at the 6 o'clock position, remove the sensor valve stem nut and push the sensor by hand into the tire (with the cap on). 3. Using a suitable tire machine, separate both beads of the tire from the wheel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 2960 4. CAUTION: Care should be taken not to damage the tire pressure sensor while separating the outside bead of tire from the wheel. Place the wheel and tire on the turntable of the tire machine, index-mark the valve stem and wheel weight positions, lubricate the bead of the tire and dismount the outside bead of the tire from the wheel. 5. Remove the tire pressure sensor from the tire. 6. Remove and discard the grommet from the tire pressure sensor. Installation NOTE: The vehicle is equipped with a light blue-colored tire pressure sensor. When installing new components, use only this tire pressure sensor. The TPM's will not operate correctly if black-colored tire pressure sensors are installed. 1. NOTE: Install a new sensor grommet or an air leak can occur. Install a new grommet on the tire pressure sensor. 2. NOTE: Do not allow the tire to rotate relative to the rim while mounting the tire. Lubricate and mount the outside and inside bead of the tire to the rim. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 2961 3. CAUTION: Overtightening the tire pressure sensor valve stem nut can damage the tire pressure sensor, undertightening can cause air leaks. NOTE: Sensor position is critical for correct sensor operation. The "flat" side of the sensor must be facing the wheel and the "slanted" side of the sensor must be facing away from the wheel. When properly installed, there will be a very small gap between the sensor and the wheel. NOTE: Tightening the nut to 5 Nm (44 inch lbs.) equals approximately 2 clockwise turns after the nut has been tightened by hand. Push the side wall of the tire and install the tire pressure sensor. Tighten the nut to 5 Nm (44 inch lbs.). 4. CAUTION: Use only special tool 204-354 anytime tire pressures are measured to be sure that accurate values are obtained. CAUTION: Place the air chuck straight on the valve stem to inflate the tire. Do not cock the air chuck during the inflation cycle. Doing so can damage the valve stem and cause air leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 2962 CAUTION: Ford recommends using a round head air chuck on tire pressure sensors; it is not recommended to use air chucks with long shanks. Doing so can cause tire pressure sensor valve stem damage and loss of tire pressure. CAUTION: Use only OEM valve caps (aluminum or plastic valve caps) with the tire pressure sensors. Do not use brass-threaded valve caps with the tire pressure sensors. Inflate the tire to the pressure specified on the safety certification sticker located on the driver or door pillar. 5. Install the wheel and tire assembly. 6. Train the tire pressure sensors. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Description and Operation Low Tire Pressure Indicator: Description and Operation UNDERSTANDING YOUR TIRE PRESSURE MONITORING SYSTEM (TPMS) The Tire Pressure Monitoring System measures pressure in your four road tires and sends the tire pressure readings to your vehicle every minute while you are driving and once every 6 hours when your vehicle is parked. The Low Tire Warning Lamp will turn ON if the tire pressure is 25% below the pressure listed on the Safety Compliance Certification Label (approximately 6 to 9 psi below the manufacturers recommend tire pressure). If the tire pressure increases 2 psi above the Light ON threshold, then the TPMS light will turn OFF. Once the light is illuminated, your tires are under inflated and need to be inflated to the manufacturers recommended tire pressure. Even if the light turns ON and a short time later turns OFF, your tire pressure still needs to be checked. In short, once the light has turned ON, at least one tire may be under inflated. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Description and Operation > Page 2967 Low Tire Pressure Indicator: Testing and Inspection TPM's Indicator and Vehicle Message Center Messages The TPM's indicator and vehicle message center (if equipped) sometimes displays faults that cannot be resolved by the customer. Treat these messages as TPM's faults that must be serviced. GO to Symptom Chart for the TPM's indicator operation and message center messages. See: Testing and Inspection/Symptom Related Diagnostic Procedures CAUTION: Place the air chuck straight on the valve stem to inflate the tire. Do not cock the air chuck during the inflation cycle. Doing so can damage the valve stem and cause air leaks. CAUTION: Ford recommends using a round head air chuck on tire pressure sensors; it is not recommended to use air chucks with long shanks. Doing so can cause tire pressure sensor valve stem damage and loss of tire pressure. TPM's Indicator Illuminates Continuously The TPM's indicator remains on continuously for the following condition: 1. NOTE: If the spare tire is in use, the damaged road tire must be repaired and installed on the vehicle to restore complete TPM's functionality before carrying out any diagnosis. Low Tire Pressure - The TPM's indicator is illuminated solid and the message center displays LOW TIRE PRESSURE (if equipped). This is displayed when any of the tire pressures are low. Tire pressure must be adjusted to the recommended cold placard pressure. Adjust the air pressure in tires. Refer to Information BUS for diagnosis of the CAN bus. The TPM's indicator flashes for 20 seconds after prove-out and for the following 3 reasons: 1 No communication with the TPM's Module (integral to VSM) - The TPM's indicator is illuminated when the instrument cluster (IC) has received no signals from the VSM for more than 5 seconds. If equipped, the message center displays TIRE PRESSURE MONITOR FAULT. GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures 2 Tire Pressure Sensor Fault - If equipped, the message center will display TIRE PRESSURE SENSOR FAULT when a tire pressure sensor is malfunctioning. GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures 3 Tire Pressure Monitor Fault - If equipped, the message center will display TIRE PRESSURE MONITOR FAULT when the tire pressure monitoring system is malfunctioning. GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Service and Repair Tire Pressure Module: Service and Repair Tire Pressure Monitoring System Module Removal and Installation CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: The tire pressure monitoring system (TPM's) is integral to the vehicle security module (VSM) and is not serviced separately. NOTE: A new VSM module is delivered in manufacturing mode with pre-set diagnostic trouble codes (DTC's). These DTC's require that a particular set of operations to be carried out in order to clear them and enable the module for normal operations. The pre-set DTC's are as follows: ^ B2477 - Module Configuration Failure/Mismatch ^ B2868 - Left Front Tire Pressure Sensor Fault ^ B2869 - Right Front Tire Pressure Sensor Fault ^ B2870 - Left Rear Tire Pressure Sensor Fault ^ B2871 - Right Rear Tire Pressure Sensor Fault ^ C2780 - ECU in Manufacturing Mode NOTE: A re-configured VSM may also set the above codes and will need to go through the same set of procedures as a new module to enable normal operation. 1. NOTE: The steps included in the VSM removal and installation process are critical to restoring vehicle security and tire pressure monitoring system operations and will permit a new or reconfigured module to operate as intended. Each step is designed to carry out a particular operation and clear the manufacturing mode DTC's. Once these DTC's are cleared, the new or reconfigured module will enter into normal operating mode. Remove the VSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection Tire Pressure Sensor: Testing and Inspection Sensor Training (Reset Procedure) NOTE: The tire pressure monitoring system is not affected by wheel and tire rotation. NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area without radio frequency (RF) noise. RF noise is generated by electrical motor and appliance operation, cellular telephones and remote transmitters, power inverters and portable entertainment equipment. 1. Turn the ignition switch to the OFF position. 2. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. Do not wait more than 1 minute between each key cycle. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. Do not wait more than 1 minute between each key cycle. 6. The horn will sound once and the TPMS indicator will flash if train mode has been entered successfully. If equipped, the message center displays "TRAIN LF TIRE", place the special tool on the valve stem of the LF tire pressure sensor. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the TPMS module. 7. Within 2 minutes after the horn sounds, place the special tool on the valve stem of the RF tire pressure sensor. NOTE: If the VSM (TPMS module integral to VSM) does not recognize any 1 of the 4 tire pressure sensors during the tire training procedure, the horn will sound twice and the message center (if equipped) will display "TIRE NOT TRAINED REPEAT" and the procedure must be repeated. 8. Repeat Step 7 for the RR and LR tires. When the tire training procedure is complete, the horn will sound once and the message center (if equipped) will display "TIRE TRAINING MODE COMPLETE". Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 2974 Tire Pressure Sensor: Service and Repair Tire Pressure Sensor Special Tools CAUTION: Use only special tool 204-354 anytime tire pressures are measured to be sure that accurate values are obtained. CAUTION: Place the air chuck straight on the valve stem to inflate the tire. Do not cock the air chuck during the inflation cycle. Doing so can damage the valve stem and cause air leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 2975 CAUTION: Ford recommends using a round head air chuck on tire pressure sensors; it is not recommended to use air chucks with long shanks. Doing so can cause tire pressure sensor valve stem damage and loss of tire pressure. Removal NOTE: The vehicle is equipped with a light blue-colored tire pressure sensor. When installing new components, use only this tire pressure sensor. The tire pressure monitoring system (TPM's) will not operate correctly if black-colored tire pressure sensors are installed. 1. Remove the wheel and tire assembly. 2. CAUTION: Do not remove the valve stem core to relieve the tire pressure. CAUTION: If the valve stem core has been removed from the valve stem, reinstall the original valve stem core. If the original valve stem core is damaged, a nickel-plated core must be installed. Failure to use a nickel-plated core will result in corrosion and the possible loss of tire pressure. NOTE: Release the tire pressure by removing the sensor valve stem nut. With the valve stem at the 6 o'clock position, remove the sensor valve stem nut and push the sensor by hand into the tire (with the cap on). 3. Using a suitable tire machine, separate both beads of the tire from the wheel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 2976 4. CAUTION: Care should be taken not to damage the tire pressure sensor while separating the outside bead of tire from the wheel. Place the wheel and tire on the turntable of the tire machine, index-mark the valve stem and wheel weight positions, lubricate the bead of the tire and dismount the outside bead of the tire from the wheel. 5. Remove the tire pressure sensor from the tire. 6. Remove and discard the grommet from the tire pressure sensor. Installation NOTE: The vehicle is equipped with a light blue-colored tire pressure sensor. When installing new components, use only this tire pressure sensor. The TPM's will not operate correctly if black-colored tire pressure sensors are installed. 1. NOTE: Install a new sensor grommet or an air leak can occur. Install a new grommet on the tire pressure sensor. 2. NOTE: Do not allow the tire to rotate relative to the rim while mounting the tire. Lubricate and mount the outside and inside bead of the tire to the rim. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 2977 3. CAUTION: Overtightening the tire pressure sensor valve stem nut can damage the tire pressure sensor, undertightening can cause air leaks. NOTE: Sensor position is critical for correct sensor operation. The "flat" side of the sensor must be facing the wheel and the "slanted" side of the sensor must be facing away from the wheel. When properly installed, there will be a very small gap between the sensor and the wheel. NOTE: Tightening the nut to 5 Nm (44 inch lbs.) equals approximately 2 clockwise turns after the nut has been tightened by hand. Push the side wall of the tire and install the tire pressure sensor. Tighten the nut to 5 Nm (44 inch lbs.). 4. CAUTION: Use only special tool 204-354 anytime tire pressures are measured to be sure that accurate values are obtained. CAUTION: Place the air chuck straight on the valve stem to inflate the tire. Do not cock the air chuck during the inflation cycle. Doing so can damage the valve stem and cause air leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 2978 CAUTION: Ford recommends using a round head air chuck on tire pressure sensors; it is not recommended to use air chucks with long shanks. Doing so can cause tire pressure sensor valve stem damage and loss of tire pressure. CAUTION: Use only OEM valve caps (aluminum or plastic valve caps) with the tire pressure sensors. Do not use brass-threaded valve caps with the tire pressure sensors. Inflate the tire to the pressure specified on the safety certification sticker located on the driver or door pillar. 5. Install the wheel and tire assembly. 6. Train the tire pressure sensors. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection Technical Service Bulletin # 05S35 Date: 050705 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 2987 Attachment I - Administrative Information OASIS ACTIVATED? Yes. OASIS will be activated by July 5, 2005 FSA VIN LIST ACTIVATED? Yes Available through by July 5, 2005. Owner names and addresses will be available by July 18, 2005. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states provinces and countries. Accordingly you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Inspect and if necessary correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TIRE REPLACEMENT GUIDELINES ^ Tires that fail the inspection must be replaced regardless of the mileage or the remaining tread on the tire. ^ Ford Motor Company will only pay claims for the replacement tires ordered through the Ford Tire Hotline that are listed in Attachment II under Ford Approved Replacement Tire List. Upgrades to other brand and size tires are NOT allowed. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 2988 ^ Some vehicles may be equipped with a Tire Pressure Monitoring System (TPMS). Damaged TPMS sensors are not covered under this program. Follow the instructions in Attachment III to avoid damaging the TPMS sensor while dismounting the tire from the rim. ^ If a related damage condition exists that you believe to be caused by the covered condition call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted (excluding the post-repair wheel nut re-torque procedure - see below). ^ The owner letter will direct customers to the dealer to have the wheel nuts re-tightened at 500 miles (800km) after tire replacement. Dealers are to use the related damage flag to submit claims for labor operation 05S35Z (post-repair wheel nut re-torque). Approval is not required for this labor operation. This labor operation may only be claimed once after the original repair has been completed. OWNER REFUNDS ^ Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or at their option directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Refund claims that include other non-covered repairs or those judged by Ford to be excessive will not be accepted for reimbursement. ^ This safety recall (tire tread inspection) must still be performed, even if the customer has paid for a previous tire replacement Claiming a refund will not close the recall on this vehicle. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 05S35 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. RENTAL VEHICLES Ford Motor Company will pay for a rental vehicle while a replacement tire is on order except for fuel and insurance which will be at the owner's expense. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "RENTAL" plus the number of days the vehicle was used in the Miscellaneous Expense area of the recall claim form. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Enter each unique DOT code of the "new" replacement tires on the diagnostic code entry screen in the Powertrain DTC fields. The "old" replaced tire DOT codes should be entered in the Body DTC fields. ^ Refer to ACESII manual for claims preparation and submission information. ^ Enter the full part number of the replacement tire with the quantity of tires replaced. Tires will be reimbursed at AtW Dealer cost +25% (mounting balancing valve stems and wheel weights included). - Virginia Dealers: Claim the additional 15% mark-up amount as miscellaneous expense code "TIREMU". ^ Freight is not reimbursable. (Freight charges will be credited on the dealer's Ford Parts statement.) ^ Tire disposal will be reimbursed see the Tire Disposal Allowance Attachment II. ^ Dealers may claim any applicable local waste tax - enter OTHER in the miscellaneous expense area of the claim with the actual cost. ^ Refunds or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 2989 LABOR ALLOWANCES PARTS ORDERING INFORMATION The following part is necessary when changing a tire on a vehicle that is equipped with the optional Tire Pressure Monitoring System (TPMS). FORD APPROVED REPLACEMENT TIRE LIST TIRE ORDERING INFORMATION ^ Tires must be ordered through the Ford Tire Hot Line. Identify the number of tires needed and use the "05535 Replacement Tire Order Form" to order your tires. (See Attachment IV for the tire order form.) ^ Tires will begin shipping the week of July 11, 2005 ^ Orders will be fulfilled in the order they are received. ^ Ford Tire Hot Line hours are 8AM to 8PM Monday through Friday EST. TIRE DESTRUCTION / MUTILATION Tires removed from vehicles must immediately be made unusable by either cutting the bead with bolt cutters or drilling a one-inch diameter hole through the sidewall. TIRE PRICE For latest tire prices refer to the Tire Sales Tool on the website. TIRE DISPOSAL ALLOWANCE An allowance of $4.00 per tire is being provided for tire disposal. To claim the allowance enter the dollar amount as "HANDLG" in the "MISC EXPENSE" area of the claim form. SPECIAL INSTRUCTIONS FOR POST-REPAIR TORQUE PROCEDURE Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 2990 The vehicle Owner's Guide states that each wheel that is removed and reinstalled must have the wheel nuts re-tightened at 500 miles (800km) after service. This is required to permit the wheel clamping system to seat correctly so that the wheel nuts will hold a uniform clamp load and remain fully tightened. To claim this operation you must file a related damage claim using labor operation 05S35Z. This labor operation includes time to check the torque on all the wheel nuts. Attachment III - Technical Information OVERVIEW This program involves inspecting all four (4) tires of the vehicle for tread damaged caused by a piece of metal on the conveyor line during vehicle assembly. INSPECTION 1. If equipped, turn the air suspension switch to the OFF position. 2. Raise the vehicle on a hoist and inspect all four (4) tires for tread damage. See Figure 1. ^ If no tread damage is found, lower the vehicle, turn on the air suspension if equipped, and release the vehicle. ^ Any tire found to have damaged tread must be replaced. Proceed to Tire Replacement. TIRE REPLACEMENT CAUTION: Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 2991 If the vehicle is equipped with a Tire Pressure Monitoring System (TPMS), specific procedures must be followed to remove and install the tire or damage to the TPMS sensors will occur. Related damage claims for TPMS sensors will be rejected. NOTE: Vehicles equipped with TPMS can be identified by the presence of a metallic valve stem at each wheel. Vehicles without TPMS will have rubber valve stems. NOTE: While the Workshop Repair Manual does not provide actual tire replacement procedures, it does provide procedures for TPMS sensor removal and installation. To prevent damage to the sensor, it must be removed and installed during tire removal and installation. Refer to Section 204-04 of the ONLINE version of the 2006 Model Year Expedition/Navigator Workshop Repair Manual for the most up-to-date service information available. Again, related damage claims for TPMS sensors will be rejected. 1. CAUTION: Do not remove the valve core from TPMS valve stem. Remove the tire from the wheel. If the vehicle is equipped with TPMS, refer to the Workshop Repair Manual for special instructions regarding the TPMS sensor removal. 2. For vehicles without TPMS, install a new rubber valve stem. 3. Mount the new tire onto the wheel. If the vehicle is equipped with TPMS, refer to the Workshop Repair Manual for special instructions regarding the TPMS sensor installation. 4. Balance the wheel/tire assembly, then install it on the vehicle. 5. Tighten the wheel nuts to 204 Nm (150 lb-ft). 6. Lower the hoist and if equipped, turn the air suspension switch to the ON position. 7. Proceed to Tire Destruction/Mutilation. TIRE DESTRUCTION/MUTILATION Tires removed from vehicles must immediately be made unusable by either cutting the bead with bolt cutters or drilling a one-inch diameter hole through the sidewall. SPECIAL INSTRUCTIONS FOR POST REPAIR RETIGHTEN PROCEDURE WARNING: Re-tighten the wheel nuts at 800 km (500 miles) after any wheel change or any time the wheel nuts are loosened. Failure to follow these instructions may result in personal injury. The Owner Guide and workshop repair manual recommend that each wheel removed and reinstalled must have the wheel nuts re-tightened at 800 km (500 miles) after service. Wheel nut torque specification is 204 Nm (150 lb-ft). This is required to permit the wheel clamping system to seat correctly so that the wheel lug nuts will hold a uniform clamp load and remain fully tightened. To claim this operation, refer to Attachment II. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 2992 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 2993 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 2994 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 2995 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > NHTSA05V310000 > Jul > 05 > Recall - Tire Tread Inspection for Damage Tires: Recalls Recall - Tire Tread Inspection for Damage MAKE/MODELS: MODEL/BUILD YEARS: Ford/Expedition 2006 Lincoln/Navigator 2006 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V310000 MFG'S REPORT DATE: July 05, 2005 COMPONENT: Tires: Tread/Belt POTENTIAL NUMBER OF UNITS AFFECTED: 10061 SUMMARY: On certain sport utility vehicles, the front and rear tires on the driver's side of affected vehicles may have been damaged at the center tread during production. CONSEQUENCE: Over time, the damage may be sufficient to allow belt corrosion ultimately leading to a tread separation, which could result in a crash. REMEDY: Dealers will inspect all four tires (to ensure inspection of the left hand side tires that may have been rotated to the other side of the vehicle) for tire tread damage and, if necessary, replace the damaged tire. The recall began on July 13, 2005. Owners should contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S35. Please note that this program will expire on December 31, 2005. 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns Tires: Customer Interest 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns TSB 08-21-11 10/27/08 4 WHEEL DRIVE/ALL WHEEL DRIVE - WITH CONTROL TRAC - SHUDDER ON ACCELERATION/DECELERATION OR BINDING ON SLOW TURNS FORD: 1997-2008 Expedition, Explorer 2006-2008 F-150 2007-2008 Explorer Sport Trac 2008 F-150 LINCOLN: 1998-2008 Navigator 2003-2005 Aviator MERCURY: 2005 Mountaineer 2006-2008 Mountaineer ISSUE Various 1997-2008 vehicles equipped with either 4 wheel drive or all wheel drive and equipped with control trac may exhibit a shudder on acceleration/deceleration, binding in slow speed turns or noise from the front driveline and/or transfer case. The shudder/binding will occur with the vehicle being operated in the awd/auto 4x4 mode. The shudder/binding may be due to incorrect tire circumference or improper tire inflation pressures. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE THIS DOES NOT APPLY TO 2006-2008 MOUNTAINEER WITH A 4.0L ENGINE OR 2007-2008 EXPLORER AND SPORT TRAC WITH 20 INCH WHEELS. NOTE VEHICLES ON THE LIST MAY REQUIRE REPLACEMENT OF TIRE/S IF THE TIRE CIRCUMFERENCE AVERAGE BETWEEN THE FRONT AND REAR AXLES ARE OUTSIDE OF THE 1/2 INCH SPECIFICATION OR IF THE TIRE CIRCUMFERENCE FROM SIDE TO SIDE ON EITHER AXLE EXCEEDS 1/2 INCH DIFFERENCE, THE SMALLER TIRE(S) MUST BE REPLACED. NOTE REVIEW THE WARRANTY AND POLICY MANUAL FOR FORD MOTOR COMPANY TIRE REPLACEMENT WARRANTY BEFORE PERFORMING THE SERVICE PROCEDURE. NOTE ONLY USE REPLACEMENT TIRE AND WHEEL THAT ARE THE SAME SIZE, LOAD INDEX, SPEED RATING AND TYPE (SUCH AS P-METRIC VERSUS LT-METRIC OR ALL-SEASON VERSUS ALL-TERRAIN) AS THOSE ORIGINALLY PROVIDED BY FORD. THE RECOMMENDED TIRE AND WHEEL SIZE MAY BE FOUND ON EITHER THE SAFETY COMPLIANCE CERTIFICATION LABEL OR THE TIRE LABEL WHICH IS LOCATED ON THE B-PILLAR OR EDGE OF THE DRIVER'S DOOR. NOTE ON SOME 4WD MODELS, THE INITIAL SHIFT FROM 2WD TO 4WD WHILE THE VEHICLE IS MOVING CAN CAUSE A MOMENTARY CLUNK AND/OR BRIEF RATCHETING SOUND. THESE SOUNDS ARE NORMAL AS THE FRONT DRIVETRAIN COMES UP TO SPEED AND IS NOT CAUSE FOR CONCERN. 1. Review the tire label for correct tire size and tire inflation pressures located at the B-Pillar of the driver's door. 2. If the tire size does not match the label, this procedure does not apply, follow normal Workshop Manual (WSM) diagnostics. 3. If the tire size is correct, ensure tire pressures are within specifications. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 3005 4. Raise the vehicle on the hoist, refer to Workshop Manual, Section 100-02. 5. Disconnect all wiring going to the transfer case and road test. 6. Is the shudder/binding present? a. If the shudder/binding is still present, do not continue with this procedure, continue with WSM normal diagnostic for 4X4. b. If the shudder/binding is gone, proceed to Step 7. 7. Raise the vehicle on the hoist and reconnect all the wiring previously disconnected. 8. Using a tailor's tape or flexible measuring tape and measure the circumference of all four (4) tires and record the measurements. (Figure 1) 9. Calculate the average of the circumference of the two (2) front tires and calculate the average of the circumference of the two (2) rear tires. (Figure 2) 10. If the difference between these two averages is greater than 1/2" (12.7 mm), front to back or side to side, replace the smallest circumference tire(s) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 3006 and remeasure the tire averages. Refer to WSM, Section 204-04 for tire replacement. NOTE WARRANTY COVERAGE ELIGIBILITY STARTS WITH 2007 NEW VEHICLE LIMITED WARRANTY COVERAGE. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082111A 2003-2008 Expedition, 1.1 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace One (1) Tire (Do Not Use With 1007A) 082111A 1997-2002 Expedition, 1.0 Hr. 1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace One (1) Tire (Do Not Use With 1007A) 082111B 2003-2008 Expedition, 1.4 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace TWO Tires. (Do Not Use With 1007A) 082111B 1997-2002 Expedition, 1.2 Hrs. 1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Two (2) Tires (Do Not Use With 1007A) 082111C 2003-2008 Expedition, 1.7 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do Not Use With 1007A) 082111C 1997-2002 Expedition, 1.4 Hrs. 1998-2002 Navigator, 2006-2008 F-150 Harley Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 3007 Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do Not Use With 1007A) DEALER CODING CONDITION BASIC PART NO. CODE 7A195 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns Tires: All Technical Service Bulletins 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns TSB 08-21-11 10/27/08 4 WHEEL DRIVE/ALL WHEEL DRIVE - WITH CONTROL TRAC - SHUDDER ON ACCELERATION/DECELERATION OR BINDING ON SLOW TURNS FORD: 1997-2008 Expedition, Explorer 2006-2008 F-150 2007-2008 Explorer Sport Trac 2008 F-150 LINCOLN: 1998-2008 Navigator 2003-2005 Aviator MERCURY: 2005 Mountaineer 2006-2008 Mountaineer ISSUE Various 1997-2008 vehicles equipped with either 4 wheel drive or all wheel drive and equipped with control trac may exhibit a shudder on acceleration/deceleration, binding in slow speed turns or noise from the front driveline and/or transfer case. The shudder/binding will occur with the vehicle being operated in the awd/auto 4x4 mode. The shudder/binding may be due to incorrect tire circumference or improper tire inflation pressures. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE THIS DOES NOT APPLY TO 2006-2008 MOUNTAINEER WITH A 4.0L ENGINE OR 2007-2008 EXPLORER AND SPORT TRAC WITH 20 INCH WHEELS. NOTE VEHICLES ON THE LIST MAY REQUIRE REPLACEMENT OF TIRE/S IF THE TIRE CIRCUMFERENCE AVERAGE BETWEEN THE FRONT AND REAR AXLES ARE OUTSIDE OF THE 1/2 INCH SPECIFICATION OR IF THE TIRE CIRCUMFERENCE FROM SIDE TO SIDE ON EITHER AXLE EXCEEDS 1/2 INCH DIFFERENCE, THE SMALLER TIRE(S) MUST BE REPLACED. NOTE REVIEW THE WARRANTY AND POLICY MANUAL FOR FORD MOTOR COMPANY TIRE REPLACEMENT WARRANTY BEFORE PERFORMING THE SERVICE PROCEDURE. NOTE ONLY USE REPLACEMENT TIRE AND WHEEL THAT ARE THE SAME SIZE, LOAD INDEX, SPEED RATING AND TYPE (SUCH AS P-METRIC VERSUS LT-METRIC OR ALL-SEASON VERSUS ALL-TERRAIN) AS THOSE ORIGINALLY PROVIDED BY FORD. THE RECOMMENDED TIRE AND WHEEL SIZE MAY BE FOUND ON EITHER THE SAFETY COMPLIANCE CERTIFICATION LABEL OR THE TIRE LABEL WHICH IS LOCATED ON THE B-PILLAR OR EDGE OF THE DRIVER'S DOOR. NOTE ON SOME 4WD MODELS, THE INITIAL SHIFT FROM 2WD TO 4WD WHILE THE VEHICLE IS MOVING CAN CAUSE A MOMENTARY CLUNK AND/OR BRIEF RATCHETING SOUND. THESE SOUNDS ARE NORMAL AS THE FRONT DRIVETRAIN COMES UP TO SPEED AND IS NOT CAUSE FOR CONCERN. 1. Review the tire label for correct tire size and tire inflation pressures located at the B-Pillar of the driver's door. 2. If the tire size does not match the label, this procedure does not apply, follow normal Workshop Manual (WSM) diagnostics. 3. If the tire size is correct, ensure tire pressures are within specifications. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 3013 4. Raise the vehicle on the hoist, refer to Workshop Manual, Section 100-02. 5. Disconnect all wiring going to the transfer case and road test. 6. Is the shudder/binding present? a. If the shudder/binding is still present, do not continue with this procedure, continue with WSM normal diagnostic for 4X4. b. If the shudder/binding is gone, proceed to Step 7. 7. Raise the vehicle on the hoist and reconnect all the wiring previously disconnected. 8. Using a tailor's tape or flexible measuring tape and measure the circumference of all four (4) tires and record the measurements. (Figure 1) 9. Calculate the average of the circumference of the two (2) front tires and calculate the average of the circumference of the two (2) rear tires. (Figure 2) 10. If the difference between these two averages is greater than 1/2" (12.7 mm), front to back or side to side, replace the smallest circumference tire(s) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 3014 and remeasure the tire averages. Refer to WSM, Section 204-04 for tire replacement. NOTE WARRANTY COVERAGE ELIGIBILITY STARTS WITH 2007 NEW VEHICLE LIMITED WARRANTY COVERAGE. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082111A 2003-2008 Expedition, 1.1 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace One (1) Tire (Do Not Use With 1007A) 082111A 1997-2002 Expedition, 1.0 Hr. 1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace One (1) Tire (Do Not Use With 1007A) 082111B 2003-2008 Expedition, 1.4 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace TWO Tires. (Do Not Use With 1007A) 082111B 1997-2002 Expedition, 1.2 Hrs. 1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Two (2) Tires (Do Not Use With 1007A) 082111C 2003-2008 Expedition, 1.7 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do Not Use With 1007A) 082111C 1997-2002 Expedition, 1.4 Hrs. 1998-2002 Navigator, 2006-2008 F-150 Harley Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 3015 Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do Not Use With 1007A) DEALER CODING CONDITION BASIC PART NO. CODE 7A195 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection Technical Service Bulletin # 05S35 Date: 050705 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 3020 Attachment I - Administrative Information OASIS ACTIVATED? Yes. OASIS will be activated by July 5, 2005 FSA VIN LIST ACTIVATED? Yes Available through by July 5, 2005. Owner names and addresses will be available by July 18, 2005. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states provinces and countries. Accordingly you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Inspect and if necessary correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TIRE REPLACEMENT GUIDELINES ^ Tires that fail the inspection must be replaced regardless of the mileage or the remaining tread on the tire. ^ Ford Motor Company will only pay claims for the replacement tires ordered through the Ford Tire Hotline that are listed in Attachment II under Ford Approved Replacement Tire List. Upgrades to other brand and size tires are NOT allowed. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 3021 ^ Some vehicles may be equipped with a Tire Pressure Monitoring System (TPMS). Damaged TPMS sensors are not covered under this program. Follow the instructions in Attachment III to avoid damaging the TPMS sensor while dismounting the tire from the rim. ^ If a related damage condition exists that you believe to be caused by the covered condition call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted (excluding the post-repair wheel nut re-torque procedure - see below). ^ The owner letter will direct customers to the dealer to have the wheel nuts re-tightened at 500 miles (800km) after tire replacement. Dealers are to use the related damage flag to submit claims for labor operation 05S35Z (post-repair wheel nut re-torque). Approval is not required for this labor operation. This labor operation may only be claimed once after the original repair has been completed. OWNER REFUNDS ^ Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or at their option directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Refund claims that include other non-covered repairs or those judged by Ford to be excessive will not be accepted for reimbursement. ^ This safety recall (tire tread inspection) must still be performed, even if the customer has paid for a previous tire replacement Claiming a refund will not close the recall on this vehicle. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 05S35 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. RENTAL VEHICLES Ford Motor Company will pay for a rental vehicle while a replacement tire is on order except for fuel and insurance which will be at the owner's expense. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "RENTAL" plus the number of days the vehicle was used in the Miscellaneous Expense area of the recall claim form. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Enter each unique DOT code of the "new" replacement tires on the diagnostic code entry screen in the Powertrain DTC fields. The "old" replaced tire DOT codes should be entered in the Body DTC fields. ^ Refer to ACESII manual for claims preparation and submission information. ^ Enter the full part number of the replacement tire with the quantity of tires replaced. Tires will be reimbursed at AtW Dealer cost +25% (mounting balancing valve stems and wheel weights included). - Virginia Dealers: Claim the additional 15% mark-up amount as miscellaneous expense code "TIREMU". ^ Freight is not reimbursable. (Freight charges will be credited on the dealer's Ford Parts statement.) ^ Tire disposal will be reimbursed see the Tire Disposal Allowance Attachment II. ^ Dealers may claim any applicable local waste tax - enter OTHER in the miscellaneous expense area of the claim with the actual cost. ^ Refunds or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 3022 LABOR ALLOWANCES PARTS ORDERING INFORMATION The following part is necessary when changing a tire on a vehicle that is equipped with the optional Tire Pressure Monitoring System (TPMS). FORD APPROVED REPLACEMENT TIRE LIST TIRE ORDERING INFORMATION ^ Tires must be ordered through the Ford Tire Hot Line. Identify the number of tires needed and use the "05535 Replacement Tire Order Form" to order your tires. (See Attachment IV for the tire order form.) ^ Tires will begin shipping the week of July 11, 2005 ^ Orders will be fulfilled in the order they are received. ^ Ford Tire Hot Line hours are 8AM to 8PM Monday through Friday EST. TIRE DESTRUCTION / MUTILATION Tires removed from vehicles must immediately be made unusable by either cutting the bead with bolt cutters or drilling a one-inch diameter hole through the sidewall. TIRE PRICE For latest tire prices refer to the Tire Sales Tool on the website. TIRE DISPOSAL ALLOWANCE An allowance of $4.00 per tire is being provided for tire disposal. To claim the allowance enter the dollar amount as "HANDLG" in the "MISC EXPENSE" area of the claim form. SPECIAL INSTRUCTIONS FOR POST-REPAIR TORQUE PROCEDURE Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 3023 The vehicle Owner's Guide states that each wheel that is removed and reinstalled must have the wheel nuts re-tightened at 500 miles (800km) after service. This is required to permit the wheel clamping system to seat correctly so that the wheel nuts will hold a uniform clamp load and remain fully tightened. To claim this operation you must file a related damage claim using labor operation 05S35Z. This labor operation includes time to check the torque on all the wheel nuts. Attachment III - Technical Information OVERVIEW This program involves inspecting all four (4) tires of the vehicle for tread damaged caused by a piece of metal on the conveyor line during vehicle assembly. INSPECTION 1. If equipped, turn the air suspension switch to the OFF position. 2. Raise the vehicle on a hoist and inspect all four (4) tires for tread damage. See Figure 1. ^ If no tread damage is found, lower the vehicle, turn on the air suspension if equipped, and release the vehicle. ^ Any tire found to have damaged tread must be replaced. Proceed to Tire Replacement. TIRE REPLACEMENT CAUTION: Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 3024 If the vehicle is equipped with a Tire Pressure Monitoring System (TPMS), specific procedures must be followed to remove and install the tire or damage to the TPMS sensors will occur. Related damage claims for TPMS sensors will be rejected. NOTE: Vehicles equipped with TPMS can be identified by the presence of a metallic valve stem at each wheel. Vehicles without TPMS will have rubber valve stems. NOTE: While the Workshop Repair Manual does not provide actual tire replacement procedures, it does provide procedures for TPMS sensor removal and installation. To prevent damage to the sensor, it must be removed and installed during tire removal and installation. Refer to Section 204-04 of the ONLINE version of the 2006 Model Year Expedition/Navigator Workshop Repair Manual for the most up-to-date service information available. Again, related damage claims for TPMS sensors will be rejected. 1. CAUTION: Do not remove the valve core from TPMS valve stem. Remove the tire from the wheel. If the vehicle is equipped with TPMS, refer to the Workshop Repair Manual for special instructions regarding the TPMS sensor removal. 2. For vehicles without TPMS, install a new rubber valve stem. 3. Mount the new tire onto the wheel. If the vehicle is equipped with TPMS, refer to the Workshop Repair Manual for special instructions regarding the TPMS sensor installation. 4. Balance the wheel/tire assembly, then install it on the vehicle. 5. Tighten the wheel nuts to 204 Nm (150 lb-ft). 6. Lower the hoist and if equipped, turn the air suspension switch to the ON position. 7. Proceed to Tire Destruction/Mutilation. TIRE DESTRUCTION/MUTILATION Tires removed from vehicles must immediately be made unusable by either cutting the bead with bolt cutters or drilling a one-inch diameter hole through the sidewall. SPECIAL INSTRUCTIONS FOR POST REPAIR RETIGHTEN PROCEDURE WARNING: Re-tighten the wheel nuts at 800 km (500 miles) after any wheel change or any time the wheel nuts are loosened. Failure to follow these instructions may result in personal injury. The Owner Guide and workshop repair manual recommend that each wheel removed and reinstalled must have the wheel nuts re-tightened at 800 km (500 miles) after service. Wheel nut torque specification is 204 Nm (150 lb-ft). This is required to permit the wheel clamping system to seat correctly so that the wheel lug nuts will hold a uniform clamp load and remain fully tightened. To claim this operation, refer to Attachment II. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 3025 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 3026 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 3027 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 3028 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > NHTSA05V310000 > Jul > 05 > Recall - Tire Tread Inspection for Damage Tires: All Technical Service Bulletins Recall - Tire Tread Inspection for Damage MAKE/MODELS: MODEL/BUILD YEARS: Ford/Expedition 2006 Lincoln/Navigator 2006 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V310000 MFG'S REPORT DATE: July 05, 2005 COMPONENT: Tires: Tread/Belt POTENTIAL NUMBER OF UNITS AFFECTED: 10061 SUMMARY: On certain sport utility vehicles, the front and rear tires on the driver's side of affected vehicles may have been damaged at the center tread during production. CONSEQUENCE: Over time, the damage may be sufficient to allow belt corrosion ultimately leading to a tread separation, which could result in a crash. REMEDY: Dealers will inspect all four tires (to ensure inspection of the left hand side tires that may have been rotated to the other side of the vehicle) for tire tread damage and, if necessary, replace the damaged tire. The recall began on July 13, 2005. Owners should contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S35. Please note that this program will expire on December 31, 2005. 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns Tires: All Technical Service Bulletins 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns TSB 08-21-11 10/27/08 4 WHEEL DRIVE/ALL WHEEL DRIVE - WITH CONTROL TRAC - SHUDDER ON ACCELERATION/DECELERATION OR BINDING ON SLOW TURNS FORD: 1997-2008 Expedition, Explorer 2006-2008 F-150 2007-2008 Explorer Sport Trac 2008 F-150 LINCOLN: 1998-2008 Navigator 2003-2005 Aviator MERCURY: 2005 Mountaineer 2006-2008 Mountaineer ISSUE Various 1997-2008 vehicles equipped with either 4 wheel drive or all wheel drive and equipped with control trac may exhibit a shudder on acceleration/deceleration, binding in slow speed turns or noise from the front driveline and/or transfer case. The shudder/binding will occur with the vehicle being operated in the awd/auto 4x4 mode. The shudder/binding may be due to incorrect tire circumference or improper tire inflation pressures. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE THIS DOES NOT APPLY TO 2006-2008 MOUNTAINEER WITH A 4.0L ENGINE OR 2007-2008 EXPLORER AND SPORT TRAC WITH 20 INCH WHEELS. NOTE VEHICLES ON THE LIST MAY REQUIRE REPLACEMENT OF TIRE/S IF THE TIRE CIRCUMFERENCE AVERAGE BETWEEN THE FRONT AND REAR AXLES ARE OUTSIDE OF THE 1/2 INCH SPECIFICATION OR IF THE TIRE CIRCUMFERENCE FROM SIDE TO SIDE ON EITHER AXLE EXCEEDS 1/2 INCH DIFFERENCE, THE SMALLER TIRE(S) MUST BE REPLACED. NOTE REVIEW THE WARRANTY AND POLICY MANUAL FOR FORD MOTOR COMPANY TIRE REPLACEMENT WARRANTY BEFORE PERFORMING THE SERVICE PROCEDURE. NOTE ONLY USE REPLACEMENT TIRE AND WHEEL THAT ARE THE SAME SIZE, LOAD INDEX, SPEED RATING AND TYPE (SUCH AS P-METRIC VERSUS LT-METRIC OR ALL-SEASON VERSUS ALL-TERRAIN) AS THOSE ORIGINALLY PROVIDED BY FORD. THE RECOMMENDED TIRE AND WHEEL SIZE MAY BE FOUND ON EITHER THE SAFETY COMPLIANCE CERTIFICATION LABEL OR THE TIRE LABEL WHICH IS LOCATED ON THE B-PILLAR OR EDGE OF THE DRIVER'S DOOR. NOTE ON SOME 4WD MODELS, THE INITIAL SHIFT FROM 2WD TO 4WD WHILE THE VEHICLE IS MOVING CAN CAUSE A MOMENTARY CLUNK AND/OR BRIEF RATCHETING SOUND. THESE SOUNDS ARE NORMAL AS THE FRONT DRIVETRAIN COMES UP TO SPEED AND IS NOT CAUSE FOR CONCERN. 1. Review the tire label for correct tire size and tire inflation pressures located at the B-Pillar of the driver's door. 2. If the tire size does not match the label, this procedure does not apply, follow normal Workshop Manual (WSM) diagnostics. 3. If the tire size is correct, ensure tire pressures are within specifications. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 3038 4. Raise the vehicle on the hoist, refer to Workshop Manual, Section 100-02. 5. Disconnect all wiring going to the transfer case and road test. 6. Is the shudder/binding present? a. If the shudder/binding is still present, do not continue with this procedure, continue with WSM normal diagnostic for 4X4. b. If the shudder/binding is gone, proceed to Step 7. 7. Raise the vehicle on the hoist and reconnect all the wiring previously disconnected. 8. Using a tailor's tape or flexible measuring tape and measure the circumference of all four (4) tires and record the measurements. (Figure 1) 9. Calculate the average of the circumference of the two (2) front tires and calculate the average of the circumference of the two (2) rear tires. (Figure 2) 10. If the difference between these two averages is greater than 1/2" (12.7 mm), front to back or side to side, replace the smallest circumference tire(s) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 3039 and remeasure the tire averages. Refer to WSM, Section 204-04 for tire replacement. NOTE WARRANTY COVERAGE ELIGIBILITY STARTS WITH 2007 NEW VEHICLE LIMITED WARRANTY COVERAGE. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082111A 2003-2008 Expedition, 1.1 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace One (1) Tire (Do Not Use With 1007A) 082111A 1997-2002 Expedition, 1.0 Hr. 1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace One (1) Tire (Do Not Use With 1007A) 082111B 2003-2008 Expedition, 1.4 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace TWO Tires. (Do Not Use With 1007A) 082111B 1997-2002 Expedition, 1.2 Hrs. 1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Two (2) Tires (Do Not Use With 1007A) 082111C 2003-2008 Expedition, 1.7 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do Not Use With 1007A) 082111C 1997-2002 Expedition, 1.4 Hrs. 1998-2002 Navigator, 2006-2008 F-150 Harley Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 3040 Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do Not Use With 1007A) DEALER CODING CONDITION BASIC PART NO. CODE 7A195 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection Technical Service Bulletin # 05S35 Date: 050705 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 3046 Attachment I - Administrative Information OASIS ACTIVATED? Yes. OASIS will be activated by July 5, 2005 FSA VIN LIST ACTIVATED? Yes Available through by July 5, 2005. Owner names and addresses will be available by July 18, 2005. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states provinces and countries. Accordingly you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Inspect and if necessary correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TIRE REPLACEMENT GUIDELINES ^ Tires that fail the inspection must be replaced regardless of the mileage or the remaining tread on the tire. ^ Ford Motor Company will only pay claims for the replacement tires ordered through the Ford Tire Hotline that are listed in Attachment II under Ford Approved Replacement Tire List. Upgrades to other brand and size tires are NOT allowed. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 3047 ^ Some vehicles may be equipped with a Tire Pressure Monitoring System (TPMS). Damaged TPMS sensors are not covered under this program. Follow the instructions in Attachment III to avoid damaging the TPMS sensor while dismounting the tire from the rim. ^ If a related damage condition exists that you believe to be caused by the covered condition call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted (excluding the post-repair wheel nut re-torque procedure - see below). ^ The owner letter will direct customers to the dealer to have the wheel nuts re-tightened at 500 miles (800km) after tire replacement. Dealers are to use the related damage flag to submit claims for labor operation 05S35Z (post-repair wheel nut re-torque). Approval is not required for this labor operation. This labor operation may only be claimed once after the original repair has been completed. OWNER REFUNDS ^ Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or at their option directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Refund claims that include other non-covered repairs or those judged by Ford to be excessive will not be accepted for reimbursement. ^ This safety recall (tire tread inspection) must still be performed, even if the customer has paid for a previous tire replacement Claiming a refund will not close the recall on this vehicle. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 05S35 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. RENTAL VEHICLES Ford Motor Company will pay for a rental vehicle while a replacement tire is on order except for fuel and insurance which will be at the owner's expense. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "RENTAL" plus the number of days the vehicle was used in the Miscellaneous Expense area of the recall claim form. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Enter each unique DOT code of the "new" replacement tires on the diagnostic code entry screen in the Powertrain DTC fields. The "old" replaced tire DOT codes should be entered in the Body DTC fields. ^ Refer to ACESII manual for claims preparation and submission information. ^ Enter the full part number of the replacement tire with the quantity of tires replaced. Tires will be reimbursed at AtW Dealer cost +25% (mounting balancing valve stems and wheel weights included). - Virginia Dealers: Claim the additional 15% mark-up amount as miscellaneous expense code "TIREMU". ^ Freight is not reimbursable. (Freight charges will be credited on the dealer's Ford Parts statement.) ^ Tire disposal will be reimbursed see the Tire Disposal Allowance Attachment II. ^ Dealers may claim any applicable local waste tax - enter OTHER in the miscellaneous expense area of the claim with the actual cost. ^ Refunds or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 3048 LABOR ALLOWANCES PARTS ORDERING INFORMATION The following part is necessary when changing a tire on a vehicle that is equipped with the optional Tire Pressure Monitoring System (TPMS). FORD APPROVED REPLACEMENT TIRE LIST TIRE ORDERING INFORMATION ^ Tires must be ordered through the Ford Tire Hot Line. Identify the number of tires needed and use the "05535 Replacement Tire Order Form" to order your tires. (See Attachment IV for the tire order form.) ^ Tires will begin shipping the week of July 11, 2005 ^ Orders will be fulfilled in the order they are received. ^ Ford Tire Hot Line hours are 8AM to 8PM Monday through Friday EST. TIRE DESTRUCTION / MUTILATION Tires removed from vehicles must immediately be made unusable by either cutting the bead with bolt cutters or drilling a one-inch diameter hole through the sidewall. TIRE PRICE For latest tire prices refer to the Tire Sales Tool on the website. TIRE DISPOSAL ALLOWANCE An allowance of $4.00 per tire is being provided for tire disposal. To claim the allowance enter the dollar amount as "HANDLG" in the "MISC EXPENSE" area of the claim form. SPECIAL INSTRUCTIONS FOR POST-REPAIR TORQUE PROCEDURE Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 3049 The vehicle Owner's Guide states that each wheel that is removed and reinstalled must have the wheel nuts re-tightened at 500 miles (800km) after service. This is required to permit the wheel clamping system to seat correctly so that the wheel nuts will hold a uniform clamp load and remain fully tightened. To claim this operation you must file a related damage claim using labor operation 05S35Z. This labor operation includes time to check the torque on all the wheel nuts. Attachment III - Technical Information OVERVIEW This program involves inspecting all four (4) tires of the vehicle for tread damaged caused by a piece of metal on the conveyor line during vehicle assembly. INSPECTION 1. If equipped, turn the air suspension switch to the OFF position. 2. Raise the vehicle on a hoist and inspect all four (4) tires for tread damage. See Figure 1. ^ If no tread damage is found, lower the vehicle, turn on the air suspension if equipped, and release the vehicle. ^ Any tire found to have damaged tread must be replaced. Proceed to Tire Replacement. TIRE REPLACEMENT CAUTION: Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 3050 If the vehicle is equipped with a Tire Pressure Monitoring System (TPMS), specific procedures must be followed to remove and install the tire or damage to the TPMS sensors will occur. Related damage claims for TPMS sensors will be rejected. NOTE: Vehicles equipped with TPMS can be identified by the presence of a metallic valve stem at each wheel. Vehicles without TPMS will have rubber valve stems. NOTE: While the Workshop Repair Manual does not provide actual tire replacement procedures, it does provide procedures for TPMS sensor removal and installation. To prevent damage to the sensor, it must be removed and installed during tire removal and installation. Refer to Section 204-04 of the ONLINE version of the 2006 Model Year Expedition/Navigator Workshop Repair Manual for the most up-to-date service information available. Again, related damage claims for TPMS sensors will be rejected. 1. CAUTION: Do not remove the valve core from TPMS valve stem. Remove the tire from the wheel. If the vehicle is equipped with TPMS, refer to the Workshop Repair Manual for special instructions regarding the TPMS sensor removal. 2. For vehicles without TPMS, install a new rubber valve stem. 3. Mount the new tire onto the wheel. If the vehicle is equipped with TPMS, refer to the Workshop Repair Manual for special instructions regarding the TPMS sensor installation. 4. Balance the wheel/tire assembly, then install it on the vehicle. 5. Tighten the wheel nuts to 204 Nm (150 lb-ft). 6. Lower the hoist and if equipped, turn the air suspension switch to the ON position. 7. Proceed to Tire Destruction/Mutilation. TIRE DESTRUCTION/MUTILATION Tires removed from vehicles must immediately be made unusable by either cutting the bead with bolt cutters or drilling a one-inch diameter hole through the sidewall. SPECIAL INSTRUCTIONS FOR POST REPAIR RETIGHTEN PROCEDURE WARNING: Re-tighten the wheel nuts at 800 km (500 miles) after any wheel change or any time the wheel nuts are loosened. Failure to follow these instructions may result in personal injury. The Owner Guide and workshop repair manual recommend that each wheel removed and reinstalled must have the wheel nuts re-tightened at 800 km (500 miles) after service. Wheel nut torque specification is 204 Nm (150 lb-ft). This is required to permit the wheel clamping system to seat correctly so that the wheel lug nuts will hold a uniform clamp load and remain fully tightened. To claim this operation, refer to Attachment II. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 3051 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 3052 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 3053 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 3054 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > NHTSA05V310000 > Jul > 05 > Recall - Tire Tread Inspection for Damage Tires: All Technical Service Bulletins Recall - Tire Tread Inspection for Damage MAKE/MODELS: MODEL/BUILD YEARS: Ford/Expedition 2006 Lincoln/Navigator 2006 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V310000 MFG'S REPORT DATE: July 05, 2005 COMPONENT: Tires: Tread/Belt POTENTIAL NUMBER OF UNITS AFFECTED: 10061 SUMMARY: On certain sport utility vehicles, the front and rear tires on the driver's side of affected vehicles may have been damaged at the center tread during production. CONSEQUENCE: Over time, the damage may be sufficient to allow belt corrosion ultimately leading to a tread separation, which could result in a crash. REMEDY: Dealers will inspect all four tires (to ensure inspection of the left hand side tires that may have been rotated to the other side of the vehicle) for tire tread damage and, if necessary, replace the damaged tire. The recall began on July 13, 2005. Owners should contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S35. Please note that this program will expire on December 31, 2005. 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications FRONT WHEEL BEARINGS High Temperature 4x4 Front Axle & Wheel Bearing Grease Ford P/N .............................................................................................................................................. ...................................................... E8TZ-19590-A Ford Specification ................................................ ................................................................................................................................... ESA-M1C198-A Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 3062 Wheel Bearing: Service and Repair Wheel Bearing and Wheel Hub Removal and Installation 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 LH rear quarter trim panel. 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. Failure to follow these instructions may result in personal injury. CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. If equipped, turn the air suspension switch to the OFF position. 2. With the vehicle in NEUTRAL, position it on a hoist. 3. NOTE: Have an assistant press the brake pedal to keep the axle from rotating. Remove and discard the rear halfshaft nut and washer. ^ To install, tighten to 300 Nm (221 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 3063 4. Using a suitable hub puller, separate the outboard CV Joint from the wheel hub. 5. CAUTION: Do not allow the caliper to hang from the brake hose or damage to the hose can result. Remove the bolts and position the caliper aside. ^ Support the caliper using mechanic's wire. ^ To install, tighten to 190 Nm (140 ft. lbs.). 6. Remove the brake disc. 7. Disconnect the wheel speed sensor electrical connector and detach the wheel speed sensor harness from the retainer. 8. Remove the bolt and detach the harness from the retainers. To install, tighten the bolt to 15 Nm (11 ft. lbs.). 9. Remove the 4 wheel bearing and hub assembly bolts, the wheel bearing assembly and the wheel speed sensor as an assembly. ^ Route the sensor wiring through the access hole in the brake shield. ^ Discard the bolts. ^ To install, tighten to 185 Nm (136 ft. lbs.). 10. If necessary, remove the wheel speed sensor bolt and the wheel speed sensor from the wheel bearing and hub assembly. ^ To install, tighten to 15 Nm (13 ft. lbs.). 11. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front axle nut ....................................................................................................................................... ...................................................... 27 Nm (20 ft.lbs.) Rear axle wheel hub retainer ........................... ...................................................................................................................................... 345 Nm (254 ft.lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations > Page 3071 C1157 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Tighten the wheel nuts, using the pattern indicated, to ............................................................................................................. 204 Nm (150 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 3075 Wheel Fastener: Service and Repair Wheel Studs Special Tools 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 LH rear quarter trim panel. 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. Failure to follow these instructions may result in personal injury. CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Remove the wheel bearing and wheel hub assembly. 2. CAUTION: Never use a hammer to remove a wheel stud. Damage to the wheel hub can result. ^ Place the wheel hub in a soft jawed vice and, using the special tool, remove the wheel stud. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 3076 Installation 1. Position the new wheel stud in the wheel bearing and hub assembly, aligning the serrations in the wheel hub flange made by the original wheel stud. 2. CAUTION: Do not use power tools to install the wheel stud. The serrations on the flange can be stripped. NOTE: Do not use the wheel nut that came with the vehicle. Install 4 washers and a wheel nut on the wheel stud and tighten the wheel nut until the stud seats against the flange. 3. Remove the wheel nut and washers. ^ Discard the wheel nut. 4. Install the wheel bearing and wheel hub assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation 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 LH rear quarter trim 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. - 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 carrying out any procedure requiring the vehicle to be jacked off the ground. - Make sure the jack and jack stands are correctly 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. - If equipped with retractable running board, disable the system through the instrument cluster controls. Jacking Points - Front Jacking Points - Front The front jacking point is indicated by an arrow cutout in the frame, located behind the front tire and wheel assembly. Jacking Points - Rear Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation > Page 3080 Jacking Points - Rear CAUTION: Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and adjoining differential housing surface can occur if a floor jack or any lifting device is allowed to contact the cover at any point where the cover joins the housing. - Do not use the rear control arms as a lifting point. The rear jacking point is indicated by an arrow cutout in the frame, located in front of the rear tire and wheel assembly. LIFTING 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 LH rear quarter trim 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: Damage to suspension, exhaust and steering linkage components can occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Lifting Points - Twin Post Hoist Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation > Page 3081 Lifting Points - Twin Post Hoist Locate the front hoist adapters and rear hoist adapters (top of frame arc) as indicated. Lifting Points - Drive On Hoist Lifting Points - Drive On Hoist The vehicle is supported by tires and suspension components. Lifting Points - Floor Jack, Front Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation > Page 3082 Lifting Points - Floor Jack, Front The front can be lifted using a floor jack under the front control arm directly below the shock. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 C1451 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 > Page 3090 C1452 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Page 3091 Variable Valve Timing Actuator: Description and Operation VARIABLE CAMSHAFT TIMING (VCT) SYSTEM Overview The VCT enables rotation of the camshaft(s) relative to the crankshaft rotation as a function of engine operating conditions. There are 4 types of VCT systems. Exhaust phase shifting (EPS) system - the exhaust cam is the active cam being retarded. - Intake phase shifting (IPS) system - the intake cam is the active cam being advanced. - Dual equal phase shifting (DEPS) system - both intake and exhaust cams are phase shifted and equally advanced or retarded. - Dual independent phase shifting (DIPS) system - where both the intake and exhaust cams are shifted independently. All systems have 4 operational modes: idle, part throttle, wide open throttle (WOT), and default mode. At idle and low engine speeds with closed throttle, the powertrain control module (PCM) determines the phase angle based on air flow, engine oil temperature and engine coolant temperature. At part and wide open throttle the PCM determines the phase angle based on engine RPM, load, and throttle position. VCT systems provide reduced emissions and enhanced engine power, fuel economy and idle quality. IPS Systems also have the added benefit of improved torque. In addition, some VCT system applications can eliminate the need for an external exhaust gas recirculation (EGR) system. The elimination of the EGR system is accomplished by controlling the overlap time between the intake valve opening and exhaust valve closing. Currently, both the IPS and DEPS systems are used Variable Camshaft Timing (VCT) System Variable Camshaft Timing System The VCT system consists of an electric hydraulic positioning control solenoid, a camshaft position (CMP) sensor, and a trigger wheel. The CMP trigger wheel has a number of equally spaced teeth equal to the number (n) of cylinders on a bank plus one extra tooth (n+1). Four cylinder and V8 engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1 tooth trigger wheel. The extra tooth placed between the equally spaced teeth represents the CMP signal for that bank. A crankshaft position sensor (CKP) provides the PCM with crankshaft positioning information in 10 degree increments. 1. The PCM receives input signals from the intake air temperature (IAT) sensor, engine coolant temperature (ECT) sensor, engine oil temperature (EOT) sensor, CMP, throttle position (TP) sensor, mass air flow (MAF) sensor, and CKP to determine the operating conditions of the engine. At idle and low engine speeds with closed throttle, the PCM controls the camshaft position based on ECT, EOT, IAT, and MAF. During part and wide open throttle, the camshaft position is determined by engine RPM, load and throttle position. The VCT system does not operate until the engine is at normal operating temperature. 2. The VCT system is enabled by the PCM when the correct conditions are met. 3. The CKP signal is used as a reference for CMP positioning. 4. The VCT solenoid valve is an integral part of the VCT system. The solenoid valve controls the flow of engine oil in the VCT actuator assembly. As the PCM controls the duty cycle of the solenoid valve, oil pressure/flow advances or retards the cam timing. Duty cycles near 0% or 100% represent rapid movement of the camshaft. Retaining a fixed camshaft position is accomplished by dithering (oscillating) the solenoid valve duty cycle. The PCM calculates and determines the desired camshaft position. It continually updates the VCT solenoid duty cycle until the desired position is Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Page 3092 achieved. A difference between the desired and actual camshaft position represents a position error in the PCM VCT control loop. The PCM disables the VCT and places the camshaft in a default position if a concern is detected. A related DTC is also set when the concern is detected. 5. When the VCT solenoid is energized, engine oil is allowed to flow to the VCT actuator assembly which advances or retards the camshaft timing. One half of the VCT actuator is coupled to the camshaft and the other half is connected to the timing chain. Oil chambers between the 2 halves couple the camshaft to the timing chain. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the camshaft to rotate in either an advance or retard position depending on the oil flow. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Service and Repair Variable Valve Timing Solenoid: Service and Repair VARIABLE CAMSHAFT TIMING OIL CONTROL SOLENOID LH Shown, RH Similar. Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the variable camshaft timing (VCT) oil control solenoid electrical connector. 3. Remove the VCT oil control solenoid grommet. 4. Remove the bolt and the VCT oil control solenoid. Discard the O-ring seal. - To install, tighten to 5 Nm (44 lb-in). - Install a new O-ring seal. Lubricate the new O-ring seal with clean engine oil prior to installation. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications GENERAL SPECIFICATIONS Compression Pressure Limit Chart (Part 1) Compression Pressure Limit Chart (Part 2) The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 3099 Compression Check: Testing and Inspection Compression Test-Compression Gauge Check 1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the battery is correctly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of 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 The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart (Part 1) Compression Pressure Limit Chart (Part 2) Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 3100 Compression Test-Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If 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 (V8-5.4L VIN 5 (2006)) 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 ................................................................................................................. .............................................. 10 Nm (89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair Camshaft Gear/Sprocket: Service and Repair Special Tool(s) Removal 1. If servicing the RH camshaft phaser and sprocket, remove the RH camshaft. For additional information, refer to Camshaft - RH. See: Camshaft/Service and Repair 2. If servicing the LH camshaft phaser and sprocket, remove the LH camshaft. For additional information, refer to Camshaft - LH. See: Camshaft/Service and Repair 3. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the special tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive Components. See: Timing Components Remove the camshaft phaser and sprocket from the timing chain. 4. Inspect the front of the camshaft phaser and sprocket for missing or damaged roll pins. - If the roll pins are missing or damaged, a new camshaft phaser and sprocket must be installed. 5. Inspect the rear of the camshaft phaser and sprocket for a deformed or damaged location pin. - If the location pin is deformed or damaged, a new camshaft phaser and sprocket must be installed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair > Page 3108 6. Visually inspect the camshaft phaser and sprocket for squareness (A). If the trigger wheel or spring is deformed or damaged (B), install a new camshaft phaser and sprocket. Installation 1. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. If installing a new camshaft phaser and sprocket, transfer the original scribe mark to the new camshaft phaser and sprocket. 2. NOTICE: The timing chain must be installed in its original position onto the camshaft phaser and sprocket using the scribed marks, or damage to valves and pistons will result. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. Align the scribe marks and position the camshaft phaser and sprocket into the timing chain. 3. If servicing the RH camshaft phaser and sprocket, install the RH camshaft. For additional information, refer to Camshaft - RH. See: Camshaft/Service and Repair 4. If servicing the LH camshaft phaser and sprocket, install the LH camshaft. For additional information, refer to Camshaft - LH. See: Camshaft/Service and Repair Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures Camshaft: Service and Repair General Procedures Camshaft Journal-Diameter 1. Measure each camshaft journal diameter in two directions. ^ If out of specification, install new components as necessary. Camshaft Journal-Clearance, Plastigage Method Special Tools And Equipment Special Tool(s) NOTE: The camshaft journals must meet specifications before checking camshaft journal clearance. 1. Remove the camshaft bearing cap and lay Plastigage across the surface. 2. NOTE: Do not turn the camshaft while carrying out this procedure. Position the camshaft bearing cap and install the bolts. 3. Use Plastigage to verify the camshaft journal clearance. ^ If out of specification, install new components as necessary. Camshaft End Play Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 3113 Special Tools And Equipment Special Tool(s) 1. Use a Dial Indicator Gauge with Holding Fixture to measure camshaft end play. 2. Position the camshaft to the rear of the cylinder head. 3. Zero the indicator. 4. Move the camshaft to the front of the cylinder head. Note and record the camshaft end play. ^ If camshaft end play exceeds specifications, install new camshaft and recheck end play. ^ If camshaft end play exceeds specification after camshaft installation, install a new cylinder head. Camshaft-Lobe Surface 1. Inspect camshaft lobes for pitting or damage in the contact area. Minor pitting is acceptable outside the contact area. ^ If excessive pitting or damage is present, install new components as necessary. Camshaft Lobe Lift Special Tools And Equipment Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 3114 1. Use a Dial Indicator Gauge with Holding Fixture to measure camshaft intake exhaust lobe lift. ^ Rotate the camshaft and subtract the lowest indicator reading from the highest indicator reading to figure the camshaft lobe lift. ^ Camshaft Runout Special Tools And Equipment Special Tool(s) 1. NOTE: Camshaft journals must be within specifications before checking runout. Use a Dial Indicator Gauge with Holding Fixture to measure the camshaft runout. ^ Rotate the camshaft and subtract the lowest indicator reading from the highest indicator reading. ^ For additional information, refer to the specification chart in the appropriate engine section. ^ If out of specification, install new components as necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 3115 Camshaft: Service and Repair Camshaft - LH Special Tool(s) Material Removal NOTICE: The camshaft procedure must be followed exactly or damage to the valves and pistons will result. 1. Position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation at the 1 o'clock position. 2. Remove the LH valve cover. 3. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. Loosen and back off the LH camshaft phaser and sprocket bolt one full turn. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 3116 4. Disconnect the LH camshaft position (CMP) sensor electrical connector. 5. Remove the LH CMP sensor and the bolt. 6. NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft keyway will require one full additional rotation to 12 o'clock. The No.5 cylinder camshaft lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and the exhaust lobe on the No.5 cylinder. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 3117 7. Remove only the 3 camshaft roller followers shown in the illustration. 8. NOTICE: The camshaft roller followers must be installed in their original locations. Record camshaft roller follower locations. Failure to follow these instructions may result in engine damage. NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. NOTE: It may be necessary to push the valve down while compressing the spring. Using the special tool, remove only the 3 designated camshaft roller followers from the previous step. 9. NOTICE: The crankshaft cannot be moved past the 6 o'clock position once set or engine damage may occur. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 3118 Rotate the crankshaft clockwise, as viewed from the front, positioning the crankshaft damper spoke at the 6 o'clock position and the timing mark indentation at the 7 o'clock position. 10. NOTICE: Engine is not freewheeling. Camshaft procedure must be followed exactly or damage to valves and pistons will result. NOTE: The Timing Chain Wedge tool must be installed square to the timing chain and the engine block. NOTE: Engine front cover removed for clarity. Install the special tool in the LH timing chain as shown. 11. NOTICE: Do not remove the Timing Chain Wedge tool at any time during assembly. If the special tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive Components. See: Timing Components NOTICE: The timing chain must be installed in its original position onto the camshaft phaser and sprocket using the scribed marks, or damage to valves and pistons will result. NOTE: RH shown, LH similar. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 3119 Scribe a location mark on the timing chain and the camshaft phaser and sprocket assembly. 12. NOTICE: Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from side loading. Remove the 2 bolts and the LH cylinder head camshaft front bearing cap. 13. NOTICE: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Failure to follow these instructions may result in engine damage. Remove the remaining bolts in the sequence shown and remove the LH cylinder head camshaft bearing caps. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 3120 14. Clean and inspect the LH camshaft bearing caps. - The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material. 15. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTICE: Only use hand tools to remove the camshaft phaser and sprocket bolt or damage may occur to the camshaft or camshaft phaser and sprocket. NOTICE: Do not remove the Timing Chain Wedge tool at any time during assembly. If the special tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive Components. See: Timing Components Remove the bolt and withdraw the camshaft from the camshaft phaser and sprocket assembly, leaving the camshaft phaser and sprocket assembly in place. Discard the bolt and washer. 16. Inspect the camshaft phaser and sprocket for damage. For additional information, refer to Camshaft Phaser and Sprocket. See: In-Vehicle Repair Installation 1. Lubricate the camshaft and camshaft journals with clean engine oil. 2. NOTICE: Do not remove the Timing Chain Wedge tool at any time during assembly. If the special tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive Components. See: Timing Components NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTE: Do not allow the camshaft roller followers to move out of position when installing the camshaft. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 3121 Install the camshaft into the camshaft phaser and sprocket assembly and onto the head. Install a new camshaft phaser and sprocket bolt finger-tight. 3. NOTICE: Do not remove the Timing Chain Wedge tool at any time during assembly. If the special tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive Components. See: Timing Components NOTICE: The timing chain must be installed in its original position onto the camshaft phaser and sprocket using the scribed marks, or damage to valves and pistons will result. NOTE: RH shown, LH similar. Verify the camshaft phaser and sprocket and timing chain scribe marks are still in alignment. 4. NOTE: Do not allow the camshaft roller followers to move out of position when installing the camshaft. Install the camshaft bearing caps in their original locations. - Lubricate the camshaft bearing caps with clean engine oil. - Position the front camshaft bearing cap. - Position the remaining camshaft bearing caps. - Install the bolts loosely. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 3122 5. Tighten the bolts in the sequence shown. Tighten to 10 Nm (89 lb-in). 6. NOTE: Engine front cover removed for clarity. Remove the special tools. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 3123 7. Rotate the crankshaft a half turn counterclockwise and position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation at the 1 o'clock position. 8. Verify correct camshaft position by noting the position of the No.5 cylinder intake and exhaust camshaft lobes. 9. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to Cylinder Head. See: Cylinder Head Assembly NOTE: It may be necessary to push the valve down while compressing the spring. Using the special tool, install the 3 originally removed camshaft roller followers. 10. Install the CMP sensor and the bolt. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 3124 11. Connect the CMP electrical connector. 12. NOTICE: Only use hand tools to install the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and sprocket. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. Tighten the camshaft phaser and sprocket bolt in 2 stages: - Stage 1: Tighten to 40 Nm (30 lb-ft). - Stage 2: Tighten an additional 90°. 13. In stall the LH valve cover. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 3125 Camshaft: Service and Repair Camshaft - RH Special Tool(s) Material Removal NOTICE: The camshaft procedure must be followed exactly or damage to the valves and pistons will result. 1. Position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation at the 1 o'clock position. 2. Remove the RH valve cover. 3. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. Loosen and back off the RH camshaft phaser and sprocket bolt one full turn. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 3126 4. Disconnect the RH camshaft position (CMP) sensor electrical connector. 5. Remove the bolt and the RH CMP sensor. 6. NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft will require one full additional rotation to 12 o'clock. The No.1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and the exhaust lobe on the No.1 cylinder. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 3127 7. Remove only the 3 camshaft roller followers shown in the illustration. 8. NOTICE: The camshaft roller followers must be installed in their original locations. Record camshaft roller follower locations. Failure to follow these instructions may result in engine damage. NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. NOTE: It may be necessary to push the valve down while compressing the spring. Using the special tool, remove only the 3 designated camshaft roller followers from the previous step. 9. NOTICE: The crankshaft cannot be moved past the 6 o'clock position once set or engine damage may occur. Rotate the crankshaft clockwise, as viewed from the front, positioning the crankshaft damper spoke at the 6 o'clock position and the timing mark indentation at the 7 o'clock position. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 3128 10. NOTICE: Engine is not freewheeling. Camshaft procedure must be followed exactly or damage to valves and pistons will result. NOTE: The Timing Chain Wedge tool must be installed square to the timing chain and the engine block. NOTE: Engine front cover removed for clarity. Install the special tool in the RH timing chain as shown. 11. NOTICE: Do not remove the Timing Chain Wedge tool at any time during assembly. If the special tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive Components. NOTICE: The timing chain must be installed in its original position onto the camshaft phaser and sprocket using the scribed marks, or damage to valves and pistons will result. Scribe a location mark on the timing chain and the camshaft phaser and sprocket assembly. 12. NOTICE: Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from side loading. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 3129 Remove the 2 bolts and the RH cylinder head camshaft front bearing cap. 13. NOTICE: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Failure to follow these instructions may result in engine damage. Remove the remaining bolts in the sequence shown and remove the RH cylinder head camshaft bearing caps. 14. Clean and inspect the RH camshaft bearing caps. - The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material. 15. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTICE: Only use hand tools to remove the camshaft phaser and sprocket bolt or damage may occur to the camshaft or camshaft phaser and sprocket. NOTICE: Do not remove the Timing Chain Wedge tool at any time during assembly. If the special tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive Components. See: Timing Components Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 3130 Remove the bolt and withdraw the camshaft from the camshaft phaser and sprocket assembly, leaving the camshaft phaser and sprocket assembly in place. Discard the bolt and washer. 16. Inspect the camshaft phaser and sprocket for damage. For additional information, refer to Camshaft Phaser and Sprocket. See: Camshaft Gear/Sprocket Installation 1. Lubricate the camshaft and camshaft journals with clean engine oil. 2. NOTICE: Do not remove the Timing Chain Wedge tool at any time during assembly. If the special tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive Components. See: Timing Components NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTE: Do not allow the camshaft roller followers to move out of position when installing the camshaft. Install the camshaft into the camshaft phaser and sprocket assembly and onto the head. Install a new camshaft phaser and sprocket bolt finger-tight. 3. NOTICE: Do not remove the Timing Chain Wedge tool at any time during assembly. If the special tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive Components. See: Timing Components NOTICE: The timing chain must be installed in its original position onto the camshaft phaser and sprocket using the scribed marks, or damage to valves and pistons will result. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 3131 Verify the camshaft phaser and sprocket and timing chain scribe marks are still in alignment. 4. NOTE: Do not allow the camshaft roller followers to move out of position when installing the camshaft. Install the camshaft bearing caps in their original locations. - Lubricate the camshaft bearing caps with clean engine oil. - Position the front camshaft bearing cap. - Position the remaining camshaft bearing caps. - Install the bolts loosely. 5. Tighten the bolts in the sequence shown. - Tighten to 10 Nm (89 lb-in). 6. NOTE: Engine front cover removed for clarity. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 3132 Remove the special tool. 7. Rotate the crankshaft a half turn counterclockwise and position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation at the 1 o'clock position. 8. Verify correct camshaft position by noting the position of the No.1 cylinder intake and exhaust camshaft lobes. 9. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. NOTE: It may be necessary to push the valve down while compressing the spring. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 3133 Using the special tool, install the 3 originally removed camshaft roller followers. 10. Install the CMP sensor and the bolt. - Tighten to 10 Nm (89 lb-in). 11. Connect the CMP electrical connector. 12. NOTICE: Only use hand tools to install the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and sprocket. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. Tighten the new camshaft phaser and sprocket bolt in 2 stages: - Stage 1: Tighten to 40 Nm (30 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 3134 - stage 2: Tighten an additional 90°. 13. Install the RH valve cover. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 3135 Camshaft: Service and Repair In-Vehicle Repair Special Tool(s) Removal 1. If servicing the RH camshaft phaser and sprocket, remove the RH camshaft. For additional information, refer to Camshaft - RH. See: 2. If servicing the LH camshaft phaser and sprocket, remove the LH camshaft. For additional information, refer to Camshaft - LH. See: 3. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the special tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive Components. See: Timing Components Remove the camshaft phaser and sprocket from the timing chain. 4. Inspect the front of the camshaft phaser and sprocket for missing or damaged roll pins. - If the roll pins are missing or damaged, a new camshaft phaser and sprocket must be installed. 5. Inspect the rear of the camshaft phaser and sprocket for a deformed or damaged location pin. - If the location pin is deformed or damaged, a new camshaft phaser and sprocket must be installed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > General Procedures > Page 3136 6. Visually inspect the camshaft phaser and sprocket for squareness (A). If the trigger wheel or spring is deformed or damaged (B), install a new camshaft phaser and sprocket. Installation 1. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. If installing a new camshaft phaser and sprocket, transfer the original scribe mark to the new camshaft phaser and sprocket. 2. NOTICE: The timing chain must be installed in its original position onto the camshaft phaser and sprocket using the scribed marks, or damage to valves and pistons will result. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. Align the scribe marks and position the camshaft phaser and sprocket into the timing chain. 3. If servicing the RH camshaft phaser and sprocket, install the RH camshaft. For additional information, refer to Camshaft - RH. See: 4. If servicing the LH camshaft phaser and sprocket, install the LH camshaft. For additional information, refer to Camshaft - LH. See: Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > Customer Interest: > 06-9-11 > May > 06 > Engine - Loud Valve Train Ticking Noise Lifter / Lash Adjuster: Customer Interest Engine - Loud Valve Train Ticking Noise TSB 06-9-11 05/15/06 LOUD TICKING NOISE - 3-VALVE ENGINES - STUCK LASH ADJUSTER FORD: 2006 Mustang, Expedition, Explorer, F-150, F-250, F-350 LINCOLN: 2006 Mark LT, Navigator MERCURY: 2006 Mountaineer ISSUE Some vehicles equipped with 4.6L, 5.4L, and 6.8L 3-valve engines built between 1/11/2006 and 2/14/2006 may exhibit a loud ticking noise in the valve train area. This may be caused by a stuck/collapsed lash adjuster. ACTION Verify engine build date, isolate, and replace any stuck/collapsed lash adjuster by following the Service Procedure. SERVICE PROCEDURE 1. Check date code on the engine, located on the engine timing cover. a. Date code between 1/11/2006 and 2/14/2006, proceed to Step 2. b. Date code NOT between 1/11/2006 and 2/14/2006, this TSB does not apply, perform normal diagnostics. 2. Isolate the source of the noise to the cam cover on either Bank 1 or Bank 2. If the noise is not isolated to either cam cover, this TSB does not apply. Follow normal Workshop Manual (WSM) procedures for additional diagnostics. 3. Remove the appropriate cam cover. 4. Check for stuck/collapsed lash adjuster(s) by placing the cam lobe on the base circle and inspecting for loose cam followers as a result of the lash adjuster plunger being bottomed out. NOTE A COLLAPSED LASH ADJUSTER WILL RESULT IN EXCESSIVE CLEARANCE BETWEEN THE LASH ADJUSTER AND THE CAM FOLLOWER. NOTE WHEN CHECKING "3V" LASH ADJUSTERS - A "SPONGY" LASH ADJUSTER IS NORMAL WHEN OIL PRESSURE IS "NOT" APPLIED. 5. Replace only the affected lash adjuster(s) on the affected bank(s) following the procedures outlined in the appropriate WSM, Section 303. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 060911A 2006 Expedition/Navigator 4.6 Hrs. 5.4L 3V: Isolate And Replace Lash Adjuster(s) Right Side Of Engine (Do Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > Customer Interest: > 06-9-11 > May > 06 > Engine - Loud Valve Train Ticking Noise > Page 3145 Not Use With 6051A, 6306A, 9424A, 6584A, 6256A, 6250A, 6500A) 060911A 2006 F-150/Mark LT 5.4L 3.8 Hrs. 3V: Isolate And Replace Lash Adjuster (s) Right Side Of Engine (Do Not Use With 6051A, 6306A, 9424A, 6584A, 6256A, 6250A, 6500A) 060911A 2006 Explorer/Mountaineer 2.6 Hrs. 4.6L 3V: Isolate And Replace Lash Adjuster(s) Right Side Of Engine (Do Not Use With 6051A, 6306A, 9424A, 6584A, 6256A, 6250A, 6500A) 060911A 2006 Super Duty 5.4L 3V: 3.2 Hrs. Isolate And Replace Lash Adjuster(s) Right Side Of Engine (Do Not Use With 6051A, 6306A, 9424A, 6584A, 6256A, 6250A, 6500A) 060911A 2006 Super Duty 6.8L 3V: 4.9 Hrs. Isolate And Replace Lash Adjuster(s) Right Side Of Engine (Do Not Use With 6051A, 6306A, 9424A, 6584A, 6256A, 6250A, 6500A) 060911A 2006 Mustang 4.6L 3V: 2.3 Hrs. Isolate And Replace Lash Adjuster (s) Right Side Of Engine (Do Not Use With 6051A, 6306A, 9424A, 6584A, 6256A, 6250A, 6500A) 060911B 2006 Expedition/Navigator 2.6 Hrs. 5.4L 3V: Isolate And Replace Lash Adjuster(s) Left Side Of Engine (Do Not Use With 6051A, 6306A, 9424A, 6584A, 6256A, 6250A, 6500A) 060911B 2006 F-150/Mark LT 5.4L 2.6 Hrs. 3V: Isolate And Replace Lash Adjuster (s) Left Side Of Engine (Do Not Use With 6051A, 6306A, 9424A, 6584A, 6256A, 6250A, 6500A) 060911B 2006 Explorer/Mountaineer 2.4 Hrs. 4.6L 3V:: Isolate And Replace Lash Adjuster(s) Left Side Of Engine (Do Not Use With 6051A, 6306A, 9424A, 6584A, Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > Customer Interest: > 06-9-11 > May > 06 > Engine - Loud Valve Train Ticking Noise > Page 3146 6256A, 6250A, 6500A) 060911B 2006 Super Duty 5.4L 3V: 2.7 Hrs. Isolate And Replace Lash Adjuster(s) Left Side Of Engine (Do Not Use With 6051A, 6306A, 9424A, 6584A, 6256A, 6250A, 6500A) 060911B 2006 Super Duty 6.8L 3V: 3.1 Hrs. Isolate And Replace Lash Adjuster(s) Left Side Of Engine (Do Not Use With 6051A, 6306A, 9424A, 6584A, 6256A, 6250A, 6500A) 060911B 2006 Mustang 4.6L 3V: 2.4 Hrs. Isolate And Replace Lash Adjuster (s) Left Side Of Engine (Do Not Use With 6051A, 6306A, 9424A, 6584A, 6256A, 6250A, 6500A) 060911C 2006 Expedition/Navigator 6.6 Hrs. 5.4L 3V: Isolate And Replace Lash Adjuster(s) Both Sides Of Engine (Do Not Use With 6051A, 6306A, 9424A, 6584A, 6256A, 6250A, 6500A) 060911C 2006 F-150/Mark LT 5.4L 5.6 Hrs. 3V: Isolate And Replace Lash Adjuster (s) Both Sides Of Engine (Do Not Use With 6051A, 6306A, 9424A, 6584A, 6256A, 6250A, 6500A) 060911C 2006 Explorer/Mountaineer 4.4 Hrs. 4.6L 3V: Isolate And Replace Lash Adjuster(s) Both Sides Of Engine (Do Not Use With 6051A, 6306A, 9424A, 6584A, 6256A, 6250A, 6500A) 060911C 2006 Super Duty 5.4L 3V: 5.3 Hrs. Isolate And Replace Lash Adjuster(s) Both Sides Of Engine (Do Not Use With 6051A, 6306A, 9424A, 6584A, 6256A, 6250A, 6500A) 060911C 2006 Super Duty 6.8L 3V: 7.4 Hrs. Isolate And Replace Lash Adjuster(s) Both Sides Of Engine (Do Not Use With 6051A, 6306A, 9424A, 6584A, 6256A, 6250A, 6500A) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > Customer Interest: > 06-9-11 > May > 06 > Engine - Loud Valve Train Ticking Noise > Page 3147 060911C 2006 Mustang 4.6L 3V: 4.2 Hrs. Isolate And Replace Lash Adjuster (s) Both Sides Of Engine (Do Not Use With 6051A, 6306A, 9424A, 6584A, 6256A, 6250A, 6500A) DEALER CODING CONDITION BASIC PART NO. CODE 6500 69 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-9-11 > May > 06 > Engine - Loud Valve Train Ticking Noise Lifter / Lash Adjuster: All Technical Service Bulletins Engine - Loud Valve Train Ticking Noise TSB 06-9-11 05/15/06 LOUD TICKING NOISE - 3-VALVE ENGINES - STUCK LASH ADJUSTER FORD: 2006 Mustang, Expedition, Explorer, F-150, F-250, F-350 LINCOLN: 2006 Mark LT, Navigator MERCURY: 2006 Mountaineer ISSUE Some vehicles equipped with 4.6L, 5.4L, and 6.8L 3-valve engines built between 1/11/2006 and 2/14/2006 may exhibit a loud ticking noise in the valve train area. This may be caused by a stuck/collapsed lash adjuster. ACTION Verify engine build date, isolate, and replace any stuck/collapsed lash adjuster by following the Service Procedure. SERVICE PROCEDURE 1. Check date code on the engine, located on the engine timing cover. a. Date code between 1/11/2006 and 2/14/2006, proceed to Step 2. b. Date code NOT between 1/11/2006 and 2/14/2006, this TSB does not apply, perform normal diagnostics. 2. Isolate the source of the noise to the cam cover on either Bank 1 or Bank 2. If the noise is not isolated to either cam cover, this TSB does not apply. Follow normal Workshop Manual (WSM) procedures for additional diagnostics. 3. Remove the appropriate cam cover. 4. Check for stuck/collapsed lash adjuster(s) by placing the cam lobe on the base circle and inspecting for loose cam followers as a result of the lash adjuster plunger being bottomed out. NOTE A COLLAPSED LASH ADJUSTER WILL RESULT IN EXCESSIVE CLEARANCE BETWEEN THE LASH ADJUSTER AND THE CAM FOLLOWER. NOTE WHEN CHECKING "3V" LASH ADJUSTERS - A "SPONGY" LASH ADJUSTER IS NORMAL WHEN OIL PRESSURE IS "NOT" APPLIED. 5. Replace only the affected lash adjuster(s) on the affected bank(s) following the procedures outlined in the appropriate WSM, Section 303. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 060911A 2006 Expedition/Navigator 4.6 Hrs. 5.4L 3V: Isolate And Replace Lash Adjuster(s) Right Side Of Engine (Do Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-9-11 > May > 06 > Engine - Loud Valve Train Ticking Noise > Page 3153 Not Use With 6051A, 6306A, 9424A, 6584A, 6256A, 6250A, 6500A) 060911A 2006 F-150/Mark LT 5.4L 3.8 Hrs. 3V: Isolate And Replace Lash Adjuster (s) Right Side Of Engine (Do Not Use With 6051A, 6306A, 9424A, 6584A, 6256A, 6250A, 6500A) 060911A 2006 Explorer/Mountaineer 2.6 Hrs. 4.6L 3V: Isolate And Replace Lash Adjuster(s) Right Side Of Engine (Do Not Use With 6051A, 6306A, 9424A, 6584A, 6256A, 6250A, 6500A) 060911A 2006 Super Duty 5.4L 3V: 3.2 Hrs. Isolate And Replace Lash Adjuster(s) Right Side Of Engine (Do Not Use With 6051A, 6306A, 9424A, 6584A, 6256A, 6250A, 6500A) 060911A 2006 Super Duty 6.8L 3V: 4.9 Hrs. Isolate And Replace Lash Adjuster(s) Right Side Of Engine (Do Not Use With 6051A, 6306A, 9424A, 6584A, 6256A, 6250A, 6500A) 060911A 2006 Mustang 4.6L 3V: 2.3 Hrs. Isolate And Replace Lash Adjuster (s) Right Side Of Engine (Do Not Use With 6051A, 6306A, 9424A, 6584A, 6256A, 6250A, 6500A) 060911B 2006 Expedition/Navigator 2.6 Hrs. 5.4L 3V: Isolate And Replace Lash Adjuster(s) Left Side Of Engine (Do Not Use With 6051A, 6306A, 9424A, 6584A, 6256A, 6250A, 6500A) 060911B 2006 F-150/Mark LT 5.4L 2.6 Hrs. 3V: Isolate And Replace Lash Adjuster (s) Left Side Of Engine (Do Not Use With 6051A, 6306A, 9424A, 6584A, 6256A, 6250A, 6500A) 060911B 2006 Explorer/Mountaineer 2.4 Hrs. 4.6L 3V:: Isolate And Replace Lash Adjuster(s) Left Side Of Engine (Do Not Use With 6051A, 6306A, 9424A, 6584A, Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-9-11 > May > 06 > Engine - Loud Valve Train Ticking Noise > Page 3154 6256A, 6250A, 6500A) 060911B 2006 Super Duty 5.4L 3V: 2.7 Hrs. Isolate And Replace Lash Adjuster(s) Left Side Of Engine (Do Not Use With 6051A, 6306A, 9424A, 6584A, 6256A, 6250A, 6500A) 060911B 2006 Super Duty 6.8L 3V: 3.1 Hrs. Isolate And Replace Lash Adjuster(s) Left Side Of Engine (Do Not Use With 6051A, 6306A, 9424A, 6584A, 6256A, 6250A, 6500A) 060911B 2006 Mustang 4.6L 3V: 2.4 Hrs. Isolate And Replace Lash Adjuster (s) Left Side Of Engine (Do Not Use With 6051A, 6306A, 9424A, 6584A, 6256A, 6250A, 6500A) 060911C 2006 Expedition/Navigator 6.6 Hrs. 5.4L 3V: Isolate And Replace Lash Adjuster(s) Both Sides Of Engine (Do Not Use With 6051A, 6306A, 9424A, 6584A, 6256A, 6250A, 6500A) 060911C 2006 F-150/Mark LT 5.4L 5.6 Hrs. 3V: Isolate And Replace Lash Adjuster (s) Both Sides Of Engine (Do Not Use With 6051A, 6306A, 9424A, 6584A, 6256A, 6250A, 6500A) 060911C 2006 Explorer/Mountaineer 4.4 Hrs. 4.6L 3V: Isolate And Replace Lash Adjuster(s) Both Sides Of Engine (Do Not Use With 6051A, 6306A, 9424A, 6584A, 6256A, 6250A, 6500A) 060911C 2006 Super Duty 5.4L 3V: 5.3 Hrs. Isolate And Replace Lash Adjuster(s) Both Sides Of Engine (Do Not Use With 6051A, 6306A, 9424A, 6584A, 6256A, 6250A, 6500A) 060911C 2006 Super Duty 6.8L 3V: 7.4 Hrs. Isolate And Replace Lash Adjuster(s) Both Sides Of Engine (Do Not Use With 6051A, 6306A, 9424A, 6584A, 6256A, 6250A, 6500A) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-9-11 > May > 06 > Engine - Loud Valve Train Ticking Noise > Page 3155 060911C 2006 Mustang 4.6L 3V: 4.2 Hrs. Isolate And Replace Lash Adjuster (s) Both Sides Of Engine (Do Not Use With 6051A, 6306A, 9424A, 6584A, 6256A, 6250A, 6500A) DEALER CODING CONDITION BASIC PART NO. CODE 6500 69 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > All Other Service Bulletins for Lifter / Lash Adjuster: > 06-20-5 > Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743 Parking Assist Control Module: All Technical Service Bulletins Parking Assist System - Speaker Inop./DTC C1742/C1743 TSB 06-20-5 10/16/06 PARKING AID SPEAKER INOPERATIVE - DTCS C1742 AND C1743 FORD: 2005-2007 Five Hundred, Freestyle 2004-2006 Escape, Expedition, Explorer, F-150 2004-2007 F-250, F-350 MERCURY: 2005-2007 Montego 2004-2006 Mountaineer 2005-2006 Mariner ISSUE Some 2004-2007 vehicles equipped with the parking aid reverse sensing system (RSS) may experience low or no audible sound due to speaker issues related to the RSS. The speaker is attached to the module which may exhibit diagnostic trouble codes (DTCs) C1742 (Rear Sounder Circuit Fault) and/or C1743 (Rear Sounder Short). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Verify that DTCs C1742 and/or C1743 are present. Also, low audible or intermittent audible warning condition may exist as well. 2. If DTCs C1742 and/or C1743 are present, replace parking aid speaker on module with speaker in Speaker Kit. Follow instructions in Speaker Kit. 3. Clear DTCs and repeat check for DTCs C1742 and/or C1743. 4. If DTCs C1742 and/or C1743 go away and speaker sounds, the repair is complete. 5. If DTCs remain, follow normal diagnostics in the appropriate Workshop Manual, Section 413-13 Pinpoint Test F. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 062005A 2004-2006 Expedition: 1.2 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2007 Super Duty 0.6 Hr. 250/350: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > All Other Service Bulletins for Lifter / Lash Adjuster: > 06-20-5 > Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743 > Page 3161 062005A 2004-2005 1.1 Hrs. Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2006 Explorer/Mountaineer: 1.3 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 F-150: Replace 0.5 Hr. Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 Escape, 0.8 Hr. 2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Five 1.3 Hrs. Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Freestyle: 0.7 Hr. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR 31012AL, 31012AT) DEALER CODING CONDITION BASIC PART NO. CODE 15K864 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > All Other Service Bulletins for Lifter / Lash Adjuster: > 06-20-5 > Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743 > Page 3167 062005A 2004-2005 1.1 Hrs. Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2006 Explorer/Mountaineer: 1.3 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 F-150: Replace 0.5 Hr. Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 Escape, 0.8 Hr. 2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Five 1.3 Hrs. Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Freestyle: 0.7 Hr. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR 31012AL, 31012AT) DEALER CODING CONDITION BASIC PART NO. CODE 15K864 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > General Procedures Lifter / Lash Adjuster: Service and Repair General Procedures Hydraulic Lash Adjuster-Inspection 1. Inspect the hydraulic lash adjuster and roller follower for damage. If any damage is found, inspect the camshaft lobes and valves for damage. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > General Procedures > Page 3170 Lifter / Lash Adjuster: Service and Repair Hydraulic Lash Adjuster Hydraulic Lash Adjuster Material Removal and Installation 1. Remove the camshafts. 2. Remove the remaining camshaft roller followers from the cylinder head being serviced. 3. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations. Remove the hydraulic lash adjusters that are being serviced. 4. Inspect the hydraulic lash adjusters. 5. NOTE: Lubricate each of the hydraulic lash adjusters with clean engine oil prior to installation. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Camshaft Roller Follower Rocker Arm Assembly: Service and Repair Camshaft Roller Follower Camshaft Roller Follower Special Tool(s) Material Removal 1. Depending on the camshaft roller follower being serviced, remove the LH or RH valve cover. 2. Rotate the crankshaft until the piston for the valve being serviced is at the top of its stroke with the intake valve and the exhaust valves closed. 3. CAUTION: If the components are to be reinstalled, they must be installed in the same position. Mark the components for installation into the original location. Using the special tool, compress the valve spring and remove the camshaft roller follower. 4. Repeat the previous 2 steps for each camshaft roller follower being serviced. 5. Inspect the camshaft roller follower. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Camshaft Roller Follower > Page 3175 1. CAUTION: If the components are to be reinstalled, they must be installed in the same position. Mark the components for installation into the original locations. NOTE: Lubricate the camshaft roller followers with clean engine oil prior to installation. Using the special tool, compress the valve spring and install the camshaft roller follower. 2. Repeat the previous step for each camshaft roller follower being serviced. 3. Depending on the camshaft roller follower being serviced, install the LH or RH valve cover. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Camshaft Roller Follower > Page 3176 Rocker Arm Assembly: Service and Repair General Procedures Roller Follower-Inspection 1. Inspect the roller follower for flat spots or scoring. If any damage is found, inspect the camshaft lobes and hydraulic lash adjuster for damage. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 C1451 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 > Page 3181 C1452 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Page 3182 Variable Valve Timing Actuator: Description and Operation VARIABLE CAMSHAFT TIMING (VCT) SYSTEM Overview The VCT enables rotation of the camshaft(s) relative to the crankshaft rotation as a function of engine operating conditions. There are 4 types of VCT systems. Exhaust phase shifting (EPS) system - the exhaust cam is the active cam being retarded. - Intake phase shifting (IPS) system - the intake cam is the active cam being advanced. - Dual equal phase shifting (DEPS) system - both intake and exhaust cams are phase shifted and equally advanced or retarded. - Dual independent phase shifting (DIPS) system - where both the intake and exhaust cams are shifted independently. All systems have 4 operational modes: idle, part throttle, wide open throttle (WOT), and default mode. At idle and low engine speeds with closed throttle, the powertrain control module (PCM) determines the phase angle based on air flow, engine oil temperature and engine coolant temperature. At part and wide open throttle the PCM determines the phase angle based on engine RPM, load, and throttle position. VCT systems provide reduced emissions and enhanced engine power, fuel economy and idle quality. IPS Systems also have the added benefit of improved torque. In addition, some VCT system applications can eliminate the need for an external exhaust gas recirculation (EGR) system. The elimination of the EGR system is accomplished by controlling the overlap time between the intake valve opening and exhaust valve closing. Currently, both the IPS and DEPS systems are used Variable Camshaft Timing (VCT) System Variable Camshaft Timing System The VCT system consists of an electric hydraulic positioning control solenoid, a camshaft position (CMP) sensor, and a trigger wheel. The CMP trigger wheel has a number of equally spaced teeth equal to the number (n) of cylinders on a bank plus one extra tooth (n+1). Four cylinder and V8 engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1 tooth trigger wheel. The extra tooth placed between the equally spaced teeth represents the CMP signal for that bank. A crankshaft position sensor (CKP) provides the PCM with crankshaft positioning information in 10 degree increments. 1. The PCM receives input signals from the intake air temperature (IAT) sensor, engine coolant temperature (ECT) sensor, engine oil temperature (EOT) sensor, CMP, throttle position (TP) sensor, mass air flow (MAF) sensor, and CKP to determine the operating conditions of the engine. At idle and low engine speeds with closed throttle, the PCM controls the camshaft position based on ECT, EOT, IAT, and MAF. During part and wide open throttle, the camshaft position is determined by engine RPM, load and throttle position. The VCT system does not operate until the engine is at normal operating temperature. 2. The VCT system is enabled by the PCM when the correct conditions are met. 3. The CKP signal is used as a reference for CMP positioning. 4. The VCT solenoid valve is an integral part of the VCT system. The solenoid valve controls the flow of engine oil in the VCT actuator assembly. As the PCM controls the duty cycle of the solenoid valve, oil pressure/flow advances or retards the cam timing. Duty cycles near 0% or 100% represent rapid movement of the camshaft. Retaining a fixed camshaft position is accomplished by dithering (oscillating) the solenoid valve duty cycle. The PCM calculates and determines the desired camshaft position. It continually updates the VCT solenoid duty cycle until the desired position is Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Page 3183 achieved. A difference between the desired and actual camshaft position represents a position error in the PCM VCT control loop. The PCM disables the VCT and places the camshaft in a default position if a concern is detected. A related DTC is also set when the concern is detected. 5. When the VCT solenoid is energized, engine oil is allowed to flow to the VCT actuator assembly which advances or retards the camshaft timing. One half of the VCT actuator is coupled to the camshaft and the other half is connected to the timing chain. Oil chambers between the 2 halves couple the camshaft to the timing chain. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the camshaft to rotate in either an advance or retard position depending on the oil flow. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Rod bearing bore diameter (with assembled liners) ............................................................................................... 53.049-53.027 mm (2.0885-2.0877 inch) Rod bearing-to-crankshaft clearance .......................................................................................................................... 0.064-0.026 mm (0.0025-0.0010 inch) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications Connecting rod journal Diameter ............................................................................................................................................................. 53.003-52.983 mm (2.0867-2.0859 inch) Maximum taper .................................................................. ........................................................................................................... 0.004 mm (0.0002 inch) Maximum out-of-round between cross sections .......................................................................................................................... 0.0075 mm (0.0003 inch) Rod-to-pin clearance ................................................................................................................................................ 0.009-0.0235 mm (0.0004-0.0093 inch) Rod pin bore diameter ............................................................................................................................................ 22.012-22.024 mm (0.8666-0.8671 inch) Rod length (center-to-center) ............................................................................................................................................................ 169.1 mm (6.6575 inch) Rod maximum allowed bend ............................................................................................................................................................ 0.038 mm (0.0015 inch) Rod maximum allowed twist ........................................................................................................................................................... 0.05 mm (0.0020 inch) b Rod bearing bore diameter (with assembled liners) ............................................................................................... 53.049-53.027 mm (2.0885-2.0877 inch) Rod bearing-to-crankshaft clearance .......................................................................................................................... 0.064-0.026 mm (0.0025-0.0010 inch) Rod side clearance ..................................................................................................................................................... 0.475-0.125 mm (0.0187-0.0049 inch) b The pin bore and crank bearing bore must be parallel and in the same vertical plane within the specified total difference when measured at the ends of a 203 mm bar, 105.5 mm on each side of rod centerline. Connecting rod cap bolts First pass ............................................................................................................................................. .................................................. 43 Nm (32 ft. lbs.) Final pass ............................................................ ............................................................................................................................................ tighten 105° Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 3191 Connecting Rod: Service and Repair Connecting Rod-Cleaning CAUTION: Do not use a caustic cleaning solution or damage to connecting rods can occur. 1. NOTE: The connecting rod large end is a matched set. The connecting rod cap must be installed on the original connecting rod in the original position. Do not reverse the cap. Parts are not interchangeable. Mark and separate the parts and clean with solvent. Clean the oil passages. Connecting Rod-Large End Bore 1. Tighten the bolts to specification, then measure the bore in two directions. The difference is the connecting rod bore out-of-round. Verify the out-of-round is within specification. ^ If out of specification, install new components as necessary. Connecting Rod-Bushing Diameter 1. Measure the inner diameter of the connecting rod bushing, if equipped. Verify the diameter is within specification. ^ If out of specification, install new components as necessary. Connecting Rod-Bend Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 3192 1. Measure the connecting rod bend on a suitable alignment fixture. Follow the instructions of the fixture manufacturer. Verify the bend measurement is within specification. ^ If out of specification, install new components as necessary. Connecting Rod-Twist 1. Measure the connecting rod twist on a suitable alignment fixture. Follow the instructions of the fixture manufacturer. Verify the measurement is within specification. ^ If out of specification, install new components as necessary. Connecting Rod-Piston Pin Side Clearance 1. Measure the clearance between the connecting rod and the piston. Verify the measurement is within specification. ^ If out of specification, install new components as necessary. Connecting Rod-Bearing Journal Clearance Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 3193 Special Tools And Equipment Special Tool(s) NOTE: The crankshaft connecting rod journals must be within specifications to check the connecting rod bearing journal clearance. 1. Remove the connecting rod bearing cap. 2. Position a piece of Plastigage across the bearing surface. 3. NOTE: Do not turn the crankshaft during this step. Install and tighten to specifications, then remove the connecting rod bearing cap. 4. Measure the Plastigage to get the connecting rod bearing journal clearance. The Plastigage should be smooth and flat. A changing width indicates a tapered or damaged connecting rod or connecting rod bearing. ^ If out of specification, install new components as necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications Cylinder block Main bearing bore inside diameter ......................................................................................................................... 72.400-72.424 mm (2.850-2.851 inch) Crankshaft Main bearing journal Diameter ................................................................................................................................................. 67.481-67.505 mm (2.6567-2.6576 inch) Maximum taper .................................................................. .............................................................................................. 0.004 mm (0.0002 inch) Maximum out-of-round between cross sections ............................................................................................................. 0.0075 mm (0.0003 inch) Journal-to-cylinder block clearance .......................................................................................................... 0.048-0.024 mm (0.0019-0.0009 inch) Crankshaft maximum end play ......................................................................................................................... 0.075-0.377 mm (0.0030-0.0148 inch) Main bearing size chart Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 3197 Vertical main bearing cap bolts First pass ............................................................................................................................................. ............................................ 40 Nm (30 ft. lbs.) Final pass .................................................................. .................................................................................................................................. tighten 90° Side main bearing bolts First pass ............................................................................................................................................. ............................................ 30 Nm (22 ft. lbs.) Final pass .................................................................. .................................................................................................................................. tighten 90° Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 3198 Crankshaft Main Bearing: Service and Repair Bearing-Inspection 1. Inspect bearings for the following defects. Possible causes are shown: 1. Cratering-fatigue failure. 2. Spot polishing-incorrect seating. 3. Imbedded dirt engine oil. 4. Scratching-dirty engine oil. 5. Base exposed-poor lubrication. 6. Both edges worn-journal damaged. 7. One edge worn-journal tapered or bearing not seated. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Crankshaft Main bearing journal Diameter ................................................................................................................................................. 67.481-67.505 mm (2.6567-2.6576 inch) Maximum taper .................................................................. .............................................................................................. 0.004 mm (0.0002 inch) Maximum out-of-round between cross sections ............................................................................................................. 0.0075 mm (0.0003 inch) Journal-to-cylinder block clearance ........................................................................................................... 0.048-0.024 mm (0.0019-0.0009 inch) Connecting rod journal Diameter ....................................................................................................................................................... 53.003-52.983 mm (2.0867-2.0859 inch) Maximum taper .................................................................................................................................... ............................ 0.004 mm (0.0002 inch) Maximum out-of-round between cross sections ............................................................................................................. 0.0075 mm (0.0003 inch) Crankshaft maximum end play ......................................................................................................................... 0.075-0.377 mm (0.0030-0.0148 inch) Rod bearing-to-crankshaft clearance ............................................................................................................... 0.064-0.026 mm (0.0025-0.0010 inch) Rod side clearance ........................................................................................................................................... 0.475-0.125 mm (0.0187-0.0049 inch) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 3202 Main bearing size chart Vertical main bearing cap bolts First pass ............................................................................................................................................. ............................................ 40 Nm (30 ft. lbs.) Final pass .................................................................. .................................................................................................................................. tighten 90° Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 3203 Side main bearing bolts First pass ............................................................................................................................................. ............................................ 30 Nm (22 ft. lbs.) Final pass .................................................................. .................................................................................................................................. tighten 90° Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 3204 Crankshaft: Service and Repair Crankshaft Main Bearing Journal- Diameter 1. Measure each of the crankshaft main bearing journal diameters in at least two directions. ^^ If out of specification, install new components as necessary. Crankshaft Main Bearing Journal- Taper 1. Measure each of the crankshaft main bearing journal diameters in at least two directions at each end of the main bearing journal. ^^ If out of specification, install new components as necessary. Crankshaft Main Bearing Journal- Clearance Special Tools And Equipment Special Tool(s) NOTE: Crankshaft main bearing journals must be within specifications before checking journal clearance. 1. Remove the crankshaft main bearing caps and crankshaft main bearing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 3205 2. Lay a piece of Plastigage across the face of each crankshaft main bearing surface. 3. NOTE: Do not turn the crankshaft while carrying out this procedure. Install and remove the crankshaft main bearing cap. 4. Verify the crankshaft journal clearance. ^^ If out of specification, install new components as necessary. Crankshaft End Play Special Tools And Equipment Special Tool(s) 1. Measure the crankshaft end play. Use a Dial Indicator Gauge with Holding Fixture to measure crankshaft end play. 2. Position the crankshaft to the rear of the cylinder block. 3. Zero the indicator. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 3206 4. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play. ^ If crankshaft end play exceeds specifications, install a new crankshaft thrust washer or crankshaft thrust main bearing. Crankshaft Runout Special Tools And Equipment Special Tool(s) 1. NOTE: Crankshaft main bearing journals must be within specifications before checking runout. Use the Dial Indicator Gauge with Holding Fixture to measure the crankshaft runout. ^ ^ Rotate the crankshaft and subtract the lowest dial indicator reading from the highest dial indicator reading to figure the crankshaft runout. If it is out of specification, install new components as necessary. Crankshaft-Connecting Rod Journal Taper, Out of Round Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 3207 1. Measure the crankshaft connecting rod journal diameters in two directions perpendicular to one another at each end of the connecting rod journal. The difference in the measurements from one end to the other is the taper. Verify measurement is within the wear limit. ^ ^ If out of specification, install new components as necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair Engine Block Heater: Service and Repair Block Heater Material Removal and Installation 1. Drain the engine cooling system. 2. CAUTION: Do not loosen the block heater retaining screw more than necessary for removal. Loosen the block heater retaining screw and remove the block heater. ^ To install, tighten to 2 Nm (18 inch lbs.). 3. NOTE: Route the block heater power cable away from hot or rotating components, or damage to the cable can occur. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Page 3211 NOTE: Lubricate the block heater O-ring seal with clean engine coolant prior to installation. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug > Component Information > Service and Repair Expansion/Freeze Plug: Service and Repair Cylinder Block Core Plug Replacement Special Tools And Equipment Special Tool(s) Material Material 1. Use a slide hammer or tools suitable to remove the cylinder block core plug. 2. Inspect the cylinder block plug bore for any damage that would interfere with the correct sealing of the plug. If the cylinder block plug bore is damaged, bore for the next oversize plug. 3. NOTE: Oversize plugs are identified by the OS stamped in the flat located on the cup side of the plug. Coat the cylinder block core plug and bore lightly with High Strength Thread-locker and install the cylinder block core plug. Cup-Type 1. CAUTION: Use care during this procedure so as not to disturb or distort the cup sealing surface. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug > Component Information > Service and Repair > Page 3215 CAUTION: When installed, the flanged edge must be below the chamfered edge of the bore to effectively seal the bore. Use a tool suitable to seat the cup-type cylinder block core plug. Expansion-Type 1. CAUTION: Do not contact the crown when installing an expansion-type cylinder block core plug. This could expand the plug before seating and result in leakage. Use tool suitable to seat the expansion-type cylinder block core plug. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Using a new crankshaft pulley bolt, install the bolt and washer and tighten the bolt in 4 stages. First pass ............................................................................................................................................. .................................................. 90 Nm (66 ft. lbs.) Second pass ....................................................... .............................................................................................................................................. loosen 360° Third pass ................................................................................................................................... .......................................................... 50 Nm (37 ft. lbs.) Final pass .................................................... ...................................................................................................................................................... tighten 90° Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 3219 Harmonic Balancer - Crankshaft Pulley: Diagrams Engine - Front End Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 3220 Engine - Front End Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 3221 Engine - Lower End Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 3222 Engine - Lower End Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 3223 Engine - Lower End Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 3224 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Pulley Special Tool(s) Material Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 3225 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the engine cooling fan lower shroud. For additional information, refer to Cooling System. 3. Rotate the tensioner clockwise and remove the accessory drive belt from the crankshaft pulley. 4. Remove the crankshaft pulley bolt and washer. ^ Discard the crankshaft pulley bolt. 5. Using the special tool, remove the crankshaft pulley. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 3226 1. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep and silicone gasket remover. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley. 2. Lubricate the crankshaft pulley sealing area with clean engine oil prior to installation. 3. Using the special tool, install the crankshaft pulley. 4. Using a new crankshaft pulley bolt, install the bolt and washer and tighten the bolt in 4 stages. ^ Stage 1: Tighten to 90 Nm (66 ft. lbs.). ^ Stage 2: Loosen 360°. ^ Stage 3: Tighten to 50 Nm (37 ft. lbs.). ^ Stage 4: Tighten an additional 90°. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 3227 5. Rotate the tensioner clockwise and install the accessory drive belt onto the crankshaft pulley. 6. Install the engine cooling fan lower shroud. For additional information, refer to Cooling System. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Piston diameter (at right angle to pin bore) Grade 1 .................................................................................................................................................. 90.175-90.165 mm (3.5502-3.5498 inch) Grade 2 .................................................................................................................................................. 90.185-90.175 mm (3.5506-3.5502 inch) Grade 3 .................................................................................................................................................. 90.195-90.185 mm (3.5510-3.5506 inch) Piston-to-cylinder bore clearance (at grade size) ............................................................................................. 0.025-0.045 mm (0.0010-0.0018 inch) Ring end gap Top ...................................................................................................................................................... ............... 0.15-0.30 mm (0.006-0.012 inch) Intermediate ................................................................................................................................................... 0.25-0.50 mm (0.0098-0.0197 inch) Oil control ...................................................................................................................................................... 0.15-0.65 mm (0.0059-0.0256 inch) Ring groove width Top ...................................................................................................................................................... ........... 1.52-1.55 mm (0.0598-0.0610 inch) Intermediate ................................................................................................................................................... 1.52-1.54 mm (0.0598-0.0606 inch) Oil control .................................................................................................................................................. 3.030-3.050 mm (0.1193-0.1201 inch) Ring width Top and intermediate ..................................................................................................................................... 1.50-1.47 mm (0.0590-0.0578 inch) Ring-to-groove clearance Top ............................................................................................................................................................. 0.020-0.080 mm (0.0008-0.0031 inch) Intermediate ............................................................................................................................................... 0.030-0.070 mm (0.0012-0.0028 inch) Pin bore diameter ......................................................................................................................................... 22.008-22.014 mm (0.8665-0.8667 inch) Pin diameter ............................................................................................................................................. 22.0010-22.0030 mm (0.8662-0.8663 inch) Pin length ....................................................................... ............................................................................................................ 61.8 mm (2.43 3 inch) Pin-to-piston fit ................................................................................................................................................ 0.005-0.013 mm (0.0002-0.0005 inch) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > General Procedures Piston: Service and Repair General Procedures Piston Inspection Special Tools And Equipment Special Tool(s) CAUTION: Do not use a caustic cleaning solution or a wire brush to clean the pistons or damage can occur. 1. Clean and inspect the (1) ring lands, (2) skirts, (3) pin bosses and the (4) tops of the pistons. If wear marks, scores or glazing is found on the piston skirt, check for a bent or twisted connecting rod. 2. Use the Piston Ring Groove Scraper to clean the piston ring grooves. ^ Make sure the oil ring holes are clean. Piston-Pin to Bore Diameter Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > General Procedures > Page 3233 1. WARNING: Cover the end of the pin bore with a hand or shop rag when removing the retainer ring, since it has a tendency to spring out. Wear eye protection. NOTE: Piston and piston pins are a matched set and should not be interchanged. Measure the piston pin bore diameter in two directions on each side. Verify the diameter is within specification. ^ If out of specification, install new components as necessary. Piston-Diameter 1. Measure the piston diameter 90 degrees from the piston pin and 42 mm down from the top of the piston at the point indicated. ^ If out of specification, install new components as necessary. Piston-to Cylinder Bore Clearance Subtract the piston diameter from the cylinder bore diameter to find the piston-to-cylinder bore clearance. Piston-Selection NOTE: The cylinder bore must be within the specifications for taper and out-of-round before fitting a piston. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > General Procedures > Page 3234 1. Select a piston size based on the cylinder bore. 2. NOTE: For precision fit, new pistons are divided into three categories within each size range based on their relative position within the range. A paint spot on the new pistons indicates the position within the size range. Choose the piston with the correct paint color. ^ Piston-Ring End Gap CAUTION: Use care when fitting piston rings to avoid possible damage to the piston ring or the cylinder bore. CAUTION: Piston rings should not be transferred from one piston to another. NOTE: Cylinder bore must be within specification for taper and out-of-round. 1. Use a piston without rings to push a piston ring in a cylinder to the bottom of ring travel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > General Procedures > Page 3235 2. Use a feeler gauge to measure the top piston ring end gap and the second piston ring end gap. ^ Piston-Ring-to-Groove Clearance 1. Inspect the piston for ring land damage or accelerated wear. 2. Measure the piston ring-to-groove clearance. ^^ If out of specification, install new components as necessary. Piston-Pin Diameter 1. Measure the piston pin diameter in two directions at the points shown. Verify the diameter is within specification. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > General Procedures > Page 3236 ^^ If out of specification, install new components as necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > General Procedures > Page 3237 Piston: Service and Repair Disassembly and Assembly Piston Material Disassembly 1. Remove the piston rings from the piston. ^ Discard the piston rings. 2. Remove the piston pin retainers and the piston pin. 3. Separate the piston from the connecting rod. 4. Clean and inspect the piston and connecting rod. Assembly Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > General Procedures > Page 3238 1. NOTE: The connecting rod must be installed into the piston with identification markings toward the front. Position the connecting rod in the piston. 2. Lubricate the piston pin and pin bore with clean engine oil. 3. Install the piston pin in the piston and connecting rod assembly. 4. Install the piston pin retaining clips in the piston. 5. Lubricate the piston and the new piston rings with clean engine oil. 6. Install the piston rings onto the piston. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Piston Ring end gap Top ...................................................................................................................................................... ............... 0.15-0.30 mm (0.006-0.012 inch) Intermediate ................................................................................................................................................... 0.25-0.50 mm (0.0098-0.0197 inch) Oil control ...................................................................................................................................................... 0.15-0.65 mm (0.0059-0.0256 inch) Ring groove width Top ...................................................................................................................................................... ........... 1.52-1.55 mm (0.0598-0.0610 inch) Intermediate ................................................................................................................................................... 1.52-1.54 mm (0.0598-0.0606 inch) Oil control .................................................................................................................................................. 3.030-3.050 mm (0.1193-0.1201 inch) Ring width Top and intermediate ..................................................................................................................................... 1.50-1.47 mm (0.0590-0.0578 inch) Ring-to-groove clearance Top ............................................................................................................................................................. 0.020-0.080 mm (0.0008-0.0031 inch) Intermediate ............................................................................................................................................... 0.030-0.070 mm (0.0012-0.0028 inch) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications This engine is equipped with hydraulic valve lifters. No adjustment is required. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The electrical connector is located on the LH frame rail under the driver side door. Disconnect the electrical connector. 3. Start the engine and allow it to idle until it stalls. 4. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail pressure has been released. 5. Turn the ignition switch to the OFF position. 6. When fuel system service is complete, connect the electrical connector. 7. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 8. Install the diagnostic tool. Turn the key ON with the engine OFF. Cycle the key OFF, then ON. Select the appropriate vehicle and engine qualifier. Clear all diagnostic trouble codes (DTCs) and carry out a PCM reset. 9. Start the vehicle and check the fuel system for leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Camshaft Roller Follower Rocker Arm Assembly: Service and Repair Camshaft Roller Follower Camshaft Roller Follower Special Tool(s) Material Removal 1. Depending on the camshaft roller follower being serviced, remove the LH or RH valve cover. 2. Rotate the crankshaft until the piston for the valve being serviced is at the top of its stroke with the intake valve and the exhaust valves closed. 3. CAUTION: If the components are to be reinstalled, they must be installed in the same position. Mark the components for installation into the original location. Using the special tool, compress the valve spring and remove the camshaft roller follower. 4. Repeat the previous 2 steps for each camshaft roller follower being serviced. 5. Inspect the camshaft roller follower. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Camshaft Roller Follower > Page 3253 1. CAUTION: If the components are to be reinstalled, they must be installed in the same position. Mark the components for installation into the original locations. NOTE: Lubricate the camshaft roller followers with clean engine oil prior to installation. Using the special tool, compress the valve spring and install the camshaft roller follower. 2. Repeat the previous step for each camshaft roller follower being serviced. 3. Depending on the camshaft roller follower being serviced, install the LH or RH valve cover. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Camshaft Roller Follower > Page 3254 Rocker Arm Assembly: Service and Repair General Procedures Roller Follower-Inspection 1. Inspect the roller follower for flat spots or scoring. If any damage is found, inspect the camshaft lobes and hydraulic lash adjuster for damage. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH Valve Cover: Service and Repair Valve Cover - LH Valve Cover - LH Material Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 3259 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 3260 Removal 1. Remove the air cleaner intake pipe. For additional information, refer to Fuel Delivery and Air Induction. 2. Remove the LH ignition coils. For additional information, refer to Ignition System. 3. Remove the nut, the bolt and position the power steering reservoir and support bracket aside. 4. Disconnect the quick connect couplings and remove the positive crankcase ventilation (PCV) tube. For additional information, refer to Fuel Delivery and Air Induction. 5. Remove the bolt and position the oil level indicator tube aside. 6. Disconnect the radio ignition interference capacitor electrical connector. 7. Disconnect the variable camshaft timing (VCT) solenoid electrical connector and the wiring harness retainers. 8. Disconnect the intake manifold vacuum tube hose from the brake booster. 9. Remove the intake manifold vacuum tube assembly from the support bracket and the valve cover stud. 10. 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. Loosen the 15 fasteners and remove the LH valve cover and gasket. ^ Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 3261 ^ Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent. Installation 1. NOTE: If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep and silicone gasket remover. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head. 2. Position the LH valve cover and new gasket on the cylinder head and tighten the bolts in the sequence shown ^ Tighten to 10 Nm (89 inch lbs.). 3. Position the intake manifold vacuum tube assembly onto the support bracket and the valve cover stud. 4. Connect the intake manifold vacuum tube hose to the brake booster. 5. Connect the VCT solenoid electrical connector and the wiring harness retainers. 6. Connect the radio ignition interference capacitor electrical connector. 7. Position the oil level indicator tube and install the bolt. ^ Tighten to 10 Nm (89 inch lbs.). 8. Position the PCV tube and connect the quick connect couplings. For additional information, refer to Fuel Delivery and Air Induction. 9. Position the power steering reservoir and support bracket and install the nut. ^ Tighten to 10 Nm (89 inch lbs.). 10. Install the power steering reservoir and support bracket lower bolt. ^ Tighten to 25 Nm (18 ft. lbs.). 11. Install the LH ignition coils. For additional information, refer to Ignition System. 12. Install the air cleaner intake pipe. For additional information, refer to Fuel Delivery and Air Induction. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 3262 Valve Cover: Service and Repair Valve Cover - RH Valve Cover - RH Special Tool(s) Material Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 3263 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 3264 Removal 1. Recover the refrigerant. For additional information, refer to Heating and Air Conditioning. 2. Remove the powertrain control module (PCM) and support bracket. For additional information, refer to Computers and Control Systems. 3. Remove the RH variable camshaft timing (VCT) oil control solenoid. For additional information, refer to Computers and Control Systems. 4. Remove the RH ignition coils. For additional information, refer to Ignition System. 5. Disconnect the quick connect couplings and remove the crankcase vent tube. For additional information, refer to Fuel Delivery and Air Induction. 6. Disconnect the wiring harness retainers from the valve cover. 7. Disconnect the A/C tube spring lock couplings. ^ Discard the O-ring seals. 8. Remove the bolt and position the A/C tube aside. ^ Discard the O-ring seal. 9. 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. Loosen the 15 fasteners and remove the RH valve cover and gasket. ^ Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. ^ Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 3265 1. NOTE: If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep and silicone gasket remover. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head. 2. Position the LH valve cover and new gasket on the cylinder head and tighten the bolts in the sequence shown. ^ Tighten to 10 Nm (89 inch lbs.). 3. NOTE: Lubricate the new O-ring seals with clean refrigerant oil prior to installation. Using new O-ring seals, connect the A/C tube spring lock couplings. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 3266 4. NOTE: Lubricate the new O-ring seals with clean refrigerant oil prior to installation. Using a new O-ring seal, position the A/C tube and install the bolt. ^ Tighten to 10 Nm (89 inch lbs.). 5. Connect the wiring harness retainers to the valve cover. 6. Position the crankcase vent tube and connect the quick connect couplings. For additional information, refer to Fuel Delivery and Air Induction. 7. Install the RH ignition coils. For additional information, refer to Ignition System. 8. Install the PCM and support bracket. For additional information, refer to Computers and Control Systems. 9. Install the RH VCT oil control solenoid. For additional information, refer to Computers and Control Systems. 10. Evacuate, leak test and charge the refrigerant system. For additional information, refer to Heating and Air Conditioning. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Service and Repair Valve Guide: Service and Repair Valve-Stem to Valve Guide Clearance Special Tools And Equipment Special Tool(s) NOTE: Valve stem diameter must be within specifications before checking valve stem to valve guide clearance. 1. NOTE: If necessary, use a magnetic base. Install a Valve Stem Clearance Tool on the valve stem and install a Dial Indicator with Bracketry. Lower the valve until the Valve Stem Clearance Tool contacts the upper surface of the valve guide. 2. Move the Valve Stem Clearance Tool toward the indicator and zero the indicator. Move the Valve Stem Clearance Tool away from the indicator and note the reading. The reading will be DOUBLE the valve stem-to-valve guide clearance. Valves with oversize stems will need to be installed if out of specification. Valve-Guide Inner Diameter 1. Measure the inner diameter of the valve guides in two directions where indicated. 2. If the valve guide is not within specifications, ream the valve guide and install a valve with an oversize stem or remove the valve guide and install a new valve guide. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Service and Repair > Page 3270 Valve-Guide Reaming 1. Use a hand-reaming kit to ream the valve guide. 2. Reface the valve seat. 3. Clean the sharp edges left by reaming. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Service and Repair Valve Seat: Service and Repair Valve-Stem Diameter 1. Measure the diameter of each intake and exhaust valve stem at the points shown. Verify the diameter is within specification. ^ If out of specification, install new components as necessary. Valve-Inspection 1. Inspect the following valve areas: 1. the end of the stem for grooves or scoring 2. the valve face and the edge for pits, grooves or scores 3. the valve head for signs of burning, erosion, warpage and cracking 4. the valve margin for wear Valve-Seat Inspection Valve and Seat Refacing Measurements CAUTION: After grinding valves or valve seats, check valve clearance. 1. Check the valve head and seat. ^ Check valve angles. ^ Check margin width. ^ Be sure margin width is within specification. 2. Inspect for abnormalities on the valve face and seat. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Service and Repair > Page 3274 Valve-Seat Width 1. Measure the valve seat width. If necessary, grind the valve seat to specification. ^ Measure the intake valve seat width. ^ Measure the exhaust valve seat width. ^ Recheck the valve spring installed length after the seats have been ground, and shim the valve springs as necessary to achieve the correct installed spring length. ^ Valve-Seat Runout 1. Use the Valve Seat Runout Gauge to check valve seat runout. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > General Procedures Valve Spring: Service and Repair General Procedures Valve-Spring Installed Length 1. Measure the installed length of each valve spring. ^ If out of specification, install new components. Valve-Spring Free Length 1. Measure the free length of each valve spring. ^ If out of specification, install new components as necessary. Valve-Spring Squareness 1. NOTE: This procedure only applies to cylindrical valve springs. Measure the out-of-square on each valve spring. ^ Turn the valve spring and observe the space between the top of the valve spring and the square. Install a new valve spring if out of square. Valve Spring Strength Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > General Procedures > Page 3279 Special Tools And Equipment Special Tool(s) 1. Use a Valve/Clutch Spring Pressure Gauge to check the valve spring for correct strength at the specified valve spring length. ^ If out of specification, install new components as necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > General Procedures > Page 3280 Valve Spring: Service and Repair Valve Springs Valve Springs Special Tool(s) Removal 1. Depending on the valve spring being serviced, remove the LH or RH valve cover. 2. Remove the spark plug. For additional information, refer to Ignition System. 3. Rotate the crankshaft until the piston for the valve being serviced is at the top of its stroke with the intake valve and the exhaust valves closed. 4. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations. Using the special tool, compress the valve spring and remove the camshaft roller follower. 5. Use compressed air in the cylinder to hold both valves in position. ^ Apply a minimum of 965 kPa (140 psi) of compressed air into the cylinder. 6. CAUTION: If air pressure has forced the piston to the bottom of the cylinder, any loss of air pressure will allow the valve to fall into the cylinder. If air pressure must be removed, support the valve prior to removal. CAUTION: If the components are to be reinstalled, they must be installed in the same position. Mark the components for location. NOTE: If a valve drops into the cylinder, remove the cylinder head. Using the special tool, compress the valve spring and remove the valve spring retainer keys. 7. Remove the valve spring retainer and the valve spring. 8. Inspect the valve spring. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > General Procedures > Page 3281 Installation 1. Using the special tool, install the valve spring, the valve spring retainer and the valve spring retainer keys. 2. Relieve the air pressure from the cylinder. 3. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations. NOTE: Lubricate the camshaft roller follower with clean engine oil prior to installation. Using the special tool, compress the valve spring and install the camshaft roller follower. 4. Install the spark plug. For additional information, refer to Ignition System. 5. Depending on the valve spring being serviced, install the LH or RH valve cover. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair Valve: Service and Repair Valve-Stem Diameter 1. Measure the diameter of each intake and exhaust valve stem at the points shown. Verify the diameter is within specification. ^ If out of specification, install new components as necessary. Valve-Inspection 1. Inspect the following valve areas: 1. the end of the stem for grooves or scoring 2. the valve face and the edge for pits, grooves or scores 3. the valve head for signs of burning, erosion, warpage and cracking 4. the valve margin for wear Valve-Seat Inspection Valve and Seat Refacing Measurements CAUTION: After grinding valves or valve seats, check valve clearance. 1. Check the valve head and seat. ^ Check valve angles. ^ Check margin width. ^ Be sure margin width is within specification. 2. Inspect for abnormalities on the valve face and seat. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Page 3285 Valve-Seat Width 1. Measure the valve seat width. If necessary, grind the valve seat to specification. ^ Measure the intake valve seat width. ^ Measure the exhaust valve seat width. ^ Recheck the valve spring installed length after the seats have been ground, and shim the valve springs as necessary to achieve the correct installed spring length. ^ Valve-Seat Runout 1. Use the Valve Seat Runout Gauge to check valve seat runout. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Locations Drive Belt: Locations Accessory Drive Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Locations > Page 3290 Drive Belt: Diagrams Accessory Drive Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Locations > Page 3291 Drive Belt: Description and Operation Accessory Drive The accessory drive system: - has a single serpentine drive belt (6 ribs). - has 3 idler pulleys. - has an automatic belt tensioner. is not adjustable. The accessory drive system provides power to operate components which power other systems. These could include components such as the generator, power steering pump, and A/C compressor. Each of these components is equipped with a pulley which is driven by the accessory drive belt. The accessory drive belt is driven by the engine crankshaft pulley. One or more idler pulleys may be provided to facilitate belt routing and alignment. The automatic belt tensioner maintains correct belt tension and compensates for component wear and changes in system load. System load changes can be caused by the A/C compressor clutch engaging and disengaging, or demand changes on other systems powered by the accessory drive belt. To maintain correct operation of this stem, it is critical that the correct length drive belt be installed. The pulleys must also be correctly aligned and kept clean. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Drive Belt: Initial Inspection and Diagnostic Overview Accessory Drive Inspection and Verification CAUTION: Under no circumstances should the accessory drive belt, tensioner or pulleys be lubricated as potential damage to the belt material and tensioner damping mechanism will occur. Do not apply any fluids or belt dressing to the accessory drive belt or pulleys. 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical damage. Visual Inspection Chart 3. Eliminate all other non-belt related noises that could cause belt misdiagnosis, such as A/C compressor engagement chirp, power steering cavitations at low temperatures, variable camshaft timing (VCT) tick or generator whine. 4. If a concern is found, correct the condition before proceeding to the next step. V-Ribbed Serpentine Drive Belt With Cracks Across Ribs 5. NOTE: Up to 15 cracks in a rib over a distance of 100 mm (4.0 inch) can be considered acceptable. If damage exceeds the acceptable limit or any chunks are found to be missing from the ribs, a new belt must be installed. Check the belt for cracks. Up to 15 cracks in a rib over a distance of 100 mm (4.0 inch) can be considered acceptable. If cracks exceed this standard, install a new belt. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3294 V-Ribbed Serpentine Belt With Piling 6. The condition of the V-ribbed drive belt should be compared against the illustration and appropriate action taken. 1 Small scattered deposits of rubber material. This is not a concern, therefore, installation of a new belt is not required. 2 Longer deposit areas building up to 50 percent of the rib height. This is not considered a concern but it can result in excessive noise. If noise is apparent, install a new belt. 3 Heavy deposits building up along the grooves resulting in a possible noise and belt stability concern. If heavy deposits are apparent, install a new belt. V-Ribbed Serpentine Belt With Chunks of Rib Missing 7. There should be no chunks missing from the belt ribs. If the belt shows any evidence of this, install a new accessory drive belt. 8. If the concern is not visually evident, verify the symptom and GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3295 Drive Belt: Symptom Related Diagnostic Procedures Symptom Chart Symptom Chart (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3296 Symptom Chart (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3297 Drive Belt: Component Tests and General Diagnostics Component Tests Drive Belt Noise/Flutter Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a damaged or an incorrectly aligned grooved pulley. To correct, determine the area where the noise comes from. Check each of the pulleys in that area with a straightedge to the crankshaft pulley. Look for accessory pulleys out of position in the fore/aft direction or at an angle to the straightedge. CAUTION: Do not apply any fluids or belt dressing to the accessory drive belt or pulleys. Drive belt squeal may be an intermittent or constant noise that occurs when the drive belt slips on an accessory pulley under certain conditions. A short intermittent squeal may occur during engine start-up and shut down or during very rapid engine acceleration and decelerations, such as: ^ wide open throttle 1-2 and 2-3 shifts or 2-3 and 3-4 back out shifts on automatic transmissions. ^ wide open throttle 1-2 and 2-3 shifts and any combination of rapid downshifting on manual transmissions. These special short-term transient events are expected, and are due to the higher system inertias required to meet the electrical and cooling demands on today's vehicle systems. Constant or re-occurring drive belt squeal can occur under these 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 discharged and suction pressure that occurs after several minutes) exceeds specifications. ^ if any of the accessories are damaged or have a worn or damaged bearing. All accessories should be rotatable by hand in the unloaded condition, if not, inspect the accessory. ^ if there is evidence of fluid contamination on the accessory drive belt. When the drive belt has been exposed to fluid contamination during vehicle operation, such as leaks from the power steering system, A/C system or cooling system, clean all pulleys with soap and water, rinse with clean water and install a new accessory drive belt. If the drive belt has been exposed to fluids in a localized area during routine vehicle service, such as replacement of hoses or fluids, the drive belt and pulleys should be washed with soap and water immediately (prior to starting the engine), and rinsed with clean water. ^ if the accessory drive belt is too long. A drive belt that is too long will allow the accessory drive belt tensioner arm to go all the way to the arm travel stop under certain load conditions, which will release tension to the drive belt. If the accessory drive belt tensioner indicator is outside the normal installation wear range window, install a new accessory drive belt. ^ NOTE: The accessory drive belt tensioner arm should rotate freely without binding. Install a new accessory drive belt tensioner if the drive belt tensioner is worn or damaged. Incorrect Drive Belt Installation CAUTION: Incorrect accessory drive belt installation will cause excessive drive belt wear and can cause the drive belt to come off the pulleys. Non-standard accessory drive belts can track differently or incorrectly. If an accessory drive belt tracks incorrectly, install a new accessory drive belt to avoid performance failure or loss of the drive belt. Incorrect Installation Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3298 Correct Installation With the engine running, check accessory drive belt tracking on all pulleys. If the edge of the accessory drive belt rides beyond the edge of the pulleys, noise and premature wear will occur. Make sure the accessory drive belt rides correctly on the pulley. If an accessory drive belt tracking condition exists, proceed with these steps: ^ Visually check the accessory drive belt tensioner for damage, especially the mounting pad surface. If the accessory drive belt tensioner is not installed correctly, the mounting surface pad will be out of position. This will result in chirp and squeal noises. ^ With the engine running, visually observe the grooves in the pulleys (not the pulley flanges or the pulley forward faces) for excessive wobble. Install new components as necessary. ^ Check all accessories, mounting brackets and the accessory drive belt tensioner for any interference that would prevent the component from mounting correctly. Correct any interference condition and recheck the accessory drive belt tracking. Tighten all accessories, mounting brackets and accessory drive belt tensioner retaining hardware to specification. Recheck the accessory drive belt tracking. Belt Tensioner - Mechanical The only mechanical check that needs to be made is a check for tensioner stick grab or bind. 1. With the engine OFF, check routing of the accessory drive belt. 2. NOTE: The accessory drive belt tensioner spring is very strong and requires substantial force to release. Using a suitable, commercially available serpentine belt tensioner release tool, release the tension on the belt and detach the accessory drive belt in the area of the tensioner. 3. Using the suitable, commercially available serpentine belt tensioner release tool, move the tensioner from its relaxed position, through its full stroke and back to the relaxed position to make sure there is no stick, grab or bind, and to make sure that there is tension on the tensioner spring. 4. Rotate the tensioner pulley by hand and check for a binding, contaminated or seized condition. Install a new accessory drive belt tensioner if necessary. 5. Inspect the area surrounding the accessory drive belt tensioner for oil leaks or contamination and repair any leaks. Install a new accessory drive belt tensioner as necessary. 6. If the accessory drive belt tensioner meets the above criteria, proceed to testing the tensioner dynamically. If the accessory drive belt tensioner does not meet the above criteria, install a new tensioner. Belt Tensioner - Dynamics The accessory drive belt tensioner can be checked dynamically as follows: 1. With the engine running, observe the accessory drive belt tensioner movement. The accessory drive tensioner should move (respond) when the air conditioning clutch cycles (if equipped), or when the engine is accelerated rapidly. If the accessory drive belt tensioner movement is excessive without air conditioning clutch cycling or engine acceleration, check belt rideout. Excessive belt rideout (uneven depth of grooves in the belt) can cause excessive accessory drive belt tensioner movement. Check rideout condition by installing a new belt. If excessive accessory drive belt tensioner movement still exists, install a new accessory drive belt tensioner. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 3299 Drive Belt: Service and Repair Accessory Drive 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Diagrams Drive Belt Tensioner: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Diagrams > Page 3303 Drive Belt Tensioner: Service and Repair Accessory Drive Belt Tensioner Removal and Installation 1. Remove the cooling fan shroud. For additional information, refer to Cooling System. 2. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt from the generator pulley. 3. Remove the 3 bolts and the accessory drive belt tensioner. ^ To install, tighten to 25 Nm (18 ft. lbs.). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 06-5-1 > Mar > 06 > Engine Controls - Cold Start Rough Idle Condition Engine Mount: Customer Interest Engine Controls - Cold Start Rough Idle Condition TSB 06-5-1 03/20/06 COLD START ROUGH IDLE EXPEDITION 4X2 ONLY FORD: 2005-2006 Expedition ISSUE Some 2005-2006 Expedition 4x2 vehicles may exhibit an idle vibration during cold start at 1400 RPM, that lasts for a few seconds. The symptom is perceived as shaking of the entire vehicle when the engine is first started after being off for an extended period of time in warm weather in excess of a few hours, such as overnight, with ambient temperatures greater than 60° F (16° C). The issue is not typically accompanied by unusual engine or fan noise. It is independent of air conditioning compressor engagement (bumps, bangs, or thumps) and air suspension pump operation (audible hum or buzz accompanied by an associated vibration). ACTION Use the following Service Procedure to resolve the concern. SERVICE PROCEDURE 1. Using normal Workshop Manual diagnostics: a. Verify the integrity of the fuel system (fuel injectors, fuel pump, fuel quality) and repair as necessary. b. Check ignition system (spark plugs, ignition coils), mechanical engine operation, and repair as necessary. 2. Check the engine assembly exhaust mounting systems for ground-outs, damage, and repair as necessary. 3. If no concerns are found or cold start symptoms continue, reprogram the powertrain control module (PCM) to the latest calibration using WDS release B41.10 and higher or B42.1 and higher. This new calibration is not included in the B42 CD. Calibration files may also be obtained at the website. NOTE COLD ENGINE IDLE SPEED WILL DROP TO 1250 RPM AND WARM DRIVE IDLE SPEED WILL INCREASE TO 650 RPM. THIS CALIBRATION IS MATCHED TO THE SERVICE ENGINE/TRANSMISSION MOUNTS LISTED IN THIS TSB. DO NOT RE-INSTALL THE ORIGINAL ENGINE/TRANSMISSION MOUNTS AFTER PERFORMING THIS RECALIBRATION. 4. Replace the left hand and right hand engine mounts. Refer to the Workshop Manual, Section 303-01 - Engine Support Insulators 5. Replace the transmission mount. Refer to Workshop Manual, Section 307-01B - Transmission Insulator & Retainer Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 060501A 2005 Expedition 4X2: 3.7 Hrs. Replace Both Engine Mounts, and Transmission Mount, Reprogram The Powertrain Control Module (Do Not Use With 6038A, 6068A, 12650D, 12650D84, 050415A, Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 06-5-1 > Mar > 06 > Engine Controls - Cold Start Rough Idle Condition > Page 3312 052301A) 060501B 2006 Expedition 4X2: 3.6 Hrs. Replace Both Engine Mounts, and Transmission Mount, Reprogram The Powertrain Control Module (Do Not Use With 6038A, 6068A, 12650D, 12650D84, 050415A, 052301A) MT060501 Claim Additional Labor Actual Required As Actual Time Time Or Use SLTS Operation If Available DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: > 06-5-1 > Mar > 06 > Engine Controls - Cold Start Rough Idle Condition Engine Mount: All Technical Service Bulletins Engine Controls - Cold Start Rough Idle Condition TSB 06-5-1 03/20/06 COLD START ROUGH IDLE EXPEDITION 4X2 ONLY FORD: 2005-2006 Expedition ISSUE Some 2005-2006 Expedition 4x2 vehicles may exhibit an idle vibration during cold start at 1400 RPM, that lasts for a few seconds. The symptom is perceived as shaking of the entire vehicle when the engine is first started after being off for an extended period of time in warm weather in excess of a few hours, such as overnight, with ambient temperatures greater than 60° F (16° C). The issue is not typically accompanied by unusual engine or fan noise. It is independent of air conditioning compressor engagement (bumps, bangs, or thumps) and air suspension pump operation (audible hum or buzz accompanied by an associated vibration). ACTION Use the following Service Procedure to resolve the concern. SERVICE PROCEDURE 1. Using normal Workshop Manual diagnostics: a. Verify the integrity of the fuel system (fuel injectors, fuel pump, fuel quality) and repair as necessary. b. Check ignition system (spark plugs, ignition coils), mechanical engine operation, and repair as necessary. 2. Check the engine assembly exhaust mounting systems for ground-outs, damage, and repair as necessary. 3. If no concerns are found or cold start symptoms continue, reprogram the powertrain control module (PCM) to the latest calibration using WDS release B41.10 and higher or B42.1 and higher. This new calibration is not included in the B42 CD. Calibration files may also be obtained at the website. NOTE COLD ENGINE IDLE SPEED WILL DROP TO 1250 RPM AND WARM DRIVE IDLE SPEED WILL INCREASE TO 650 RPM. THIS CALIBRATION IS MATCHED TO THE SERVICE ENGINE/TRANSMISSION MOUNTS LISTED IN THIS TSB. DO NOT RE-INSTALL THE ORIGINAL ENGINE/TRANSMISSION MOUNTS AFTER PERFORMING THIS RECALIBRATION. 4. Replace the left hand and right hand engine mounts. Refer to the Workshop Manual, Section 303-01 - Engine Support Insulators 5. Replace the transmission mount. Refer to Workshop Manual, Section 307-01B - Transmission Insulator & Retainer Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 060501A 2005 Expedition 4X2: 3.7 Hrs. Replace Both Engine Mounts, and Transmission Mount, Reprogram The Powertrain Control Module (Do Not Use With 6038A, 6068A, 12650D, 12650D84, 050415A, Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: > 06-5-1 > Mar > 06 > Engine Controls - Cold Start Rough Idle Condition > Page 3318 052301A) 060501B 2006 Expedition 4X2: 3.6 Hrs. Replace Both Engine Mounts, and Transmission Mount, Reprogram The Powertrain Control Module (Do Not Use With 6038A, 6068A, 12650D, 12650D84, 050415A, 052301A) MT060501 Claim Additional Labor Actual Required As Actual Time Time Or Use SLTS Operation If Available DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Page 3319 Engine Mount: Service and Repair Engine Support Insulators Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Page 3320 Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Disconnect the battery ground cable. For additional information, refer to Battery. 3. Remove the air cleaner housing. For additional information, refer to Fuel Delivery and Air Induction. 4. Remove the generator. For additional information, refer to Alternator. 5. Remove the upper cooling fan shroud. For additional information, refer to Cooling System. 6. If removing the RH engine support insulator, remove the starter. For additional information, refer to Starter. 7. If removing the LH engine support insulator, remove the oil level indicator and tube. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Page 3321 8. Install the special tools. 9. Remove the 4 exhaust manifold-to-catalytic converter nuts. 10. CAUTION: Only use hand tools when removing the transmission mount-to-crossmember nuts or damage to the transmission mount can occur. Loosen the transmission mount-to-crossmember nuts. 11. Remove the 4 bolts and position the sway bar down. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Page 3322 12. CAUTION: Only use hand tools when removing the engine mount nut or damage to the engine mount can occur. Remove the RH engine mount nut. 13. CAUTION: Only use hand tools when removing the LH engine mount through bolt or damage to the cage nut can occur. NOTE: If the LH engine mount through bolt nut is missing or damaged install a new nut using service part number W7093 75. If the LH engine mount through bolt nut cage is damaged or missing, remove the cage and install a new nut using service part number W520516-S301. Remove the LH engine mount through bolt. 14. Using the special tools, raise the engine. RH engine mount Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Page 3323 15. Remove the 3 bolts and the engine mount. LH engine mount 16. If servicing the LH engine mount on a 4WD vehicle, remove the front driveshaft. 17. Remove the 3 bolts and the engine mount. Installation RH engine mount 1. CAUTION: Clean the engine mount-to-cylinder block and engine mount-to-chassis mating surfaces of any dirt or foreign material prior to installation. Position the RH engine mount and install the 3 bolts in the sequence shown. ^ Tighten to 63 Nm (46 ft. lbs.). LH engine mount 2. CAUTION: Clean the engine mount-to-cylinder block and engine mount-to-chassis mating surfaces of any dirt or foreign material prior to installation. Position the LH engine mount and install the 3 bolts in the sequence shown. ^ Tighten to 63 Nm (46 ft. lbs.). 3. If servicing the LH engine mount on a 4WD vehicle, install the front driveshaft. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Page 3324 All vehicles 4. Lower the engine into position. 5. CAUTION: Only use hand tools when removing the LH engine mount through bolt or damage to the cage nut can occur. NOTE: If the LH engine mount through bolt nut is missing or damaged install a new nut using service part number W709375. If the LH engine mount through bolt nut cage is damaged or missing, remove the cage and install a new nut using service part number W520516-S301. Install the LH engine support insulator bolt. ^ Tighten to 175 Nm (129 ft. lbs.). 6. CAUTION: Only use hand tools when installing the RH engine mount nut or damage to the engine mount can occur. Install the RH engine mount nut. ^ Tighten to 175 Nm (129 ft. lbs.). 7. CAUTION: Only use hand tools when installing the transmission mount-to-crossmember nuts or damage to the transmission mount can occur. Install the transmission mount-to-crossmember nuts. ^ Tighten to 103 Nm (76 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Page 3325 8. Position the Y-pipe and install the 4 nuts. ^ Tighten to 40 Nm (30 ft. lbs.). 9. Position the sway bar and install the 4 bolts. ^ To install, tighten to 30 Nm (22 ft. lbs.). 10. Remove the special tools. 11. If installing the LH engine mount, install the oil level indicator and tube. 12. If installing the RH engine mount, install the starter. For additional information, refer to Starter. 13. Install the upper cooling fan shroud. For additional information, refer to Cooling System. 14. Install the generator. For additional information, refer to Alternator. 15. Install the air cleaner housing. For additional information, refer to Fuel Delivery and Air Induction. 16. Connect the battery ground cable. For additional information, refer to Battery. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Diagrams Idler Pulley: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Diagrams > Page 3329 Idler Pulley: Service and Repair Accessory Drive Belt Idler Pulley Removal and Installation 1. Remove the cooling fan shroud. For additional information, refer to Cooling System. 2. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt from the generator pulley. 3. Remove the bolt and the accessory drive belt idler pulley. ^ To install, tighten to 25 Nm (18 ft. lbs.). 4. Repeat the previous step for each accessory drive belt idler pulley being serviced. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil pressure minimum at 2,000 rpm (engine at normal operating temperature) ............................................................................................ 517 kPa (75 psi) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Service and Repair Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Oil Level Indicator and Tube Material Removal and Installation 1. With the vehicle in neutral, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the oil level indicator and tube bolt. ^ To install, tighten to 10 Nm (89 inch lbs.). 3. Remove the oil level indicator and tube from the cylinder block. ^ Discard the O-ring seal. 4. NOTE: Lubricate the new oil level indicator tube O-ring seal with clean engine oil prior to installation. To install, reverse the removal procedure. ^ Install a new O-ring seal. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter ............................................................................................................................................ ............................................................. 6.6L (7.0 Qt) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 3341 Engine Oil: Fluid Type Specifications Engine Oil U.S.A. ................................................................................................................................... Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil Canada .................................................................................................................................................. Motorcraft SAE 5W-20 Super Premium Motor Oil Ford P/N .............................................................................................................................................. ........................................... XO-5W20-QSP (U.S.A) Ford P/N ............................................................ ...................................................................................................................... CXO-5W20-LSP12 (Canada) Ford Specification ......................................................................................................................................... WSS-M2C930-A with API Certification Mark NOTE: Use of synthetic or synthetic blend motor oil is not mandatory. Engine oil need only meet the requirements of Ford specification WSS-M2C930-A and the API Certification mark. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair Oil Filter Adapter: Service and Repair Oil Filter Adapter Material Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Drain the engine cooling system. For additional information, refer to Cooling System. 3. Disconnect the engine oil pressure (EOP) sensor electrical connector. 4. Disconnect the lower radiator hose from the oil filter adapter and position it aside. 5. Disconnect the degas bottle coolant hose from the oil filter adapter and position it aside. 6. Remove and discard the engine oil filter. 7. Remove the 4 bolts and the oil filter adapter. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Page 3345 ^ To install, tighten to 25 Nm (18 ft. lbs.). 8. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces. Remove and discard the oil filter adapter gasket. Clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the mating surfaces. 9. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil pan bolts First pass ............................................................................................................................................. .......................................... 2 Nm (18 inch lbs.) Second pass .............................................................. ...................................................................................................................... 20 Nm (15 ft. lbs.) Final pass ..................................................................................................................................................... ............................................... tighten 60° Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 3349 Oil Pan: Service and Repair Oil Pan Material Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Drain the engine oil. 3. Remove the 4 bolts and the frame crossmember. 4. Remove the bolt and detach the wire harness bracket. 4WD vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 3350 5. Support the front axle housing with a jack stand. 6. NOTE: Mark the bolt and bracket so that alignment can be maintained on installation. Remove the front axle housing RH mounting bolt. 7. NOTE: Mark the bolt and bracket so that alignment can be maintained on installation. Remove the front axle housing LH front mounting bolt. 8. NOTE: Mark the bolt and bracket so that alignment can be maintained on installation Remove the front axle housing LH rear mounting bolt. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 3351 9. CAUTION: Use care when lowering the front axle housing, or the vacuum lines to the axle solenoid may become disconnected or damaged. Lower the axle to allow clearance for the oil pan to be removed. All vehicles 10. NOTE: Be careful when removing the oil pan gasket. It is reusable. Remove the 16 bolts, the oil pan and the gaskets. ^ Inspect the oil pan gasket for damage. ^ If damaged, discard the oil pan gasket and the oil pan-to-oil pump gaskets. Installation All vehicles 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. Inspect the oil pan. Clean the mating surface for the oil pan with silicone gasket remover and metal surface prep. Follow the directions on the packaging. 2. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 3352 Apply silicone gasket and sealant at the crankshaft rear seal retainer plate-to-cylinder block sealing surface. 3. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface. 4. Install the oil pan gasket and the oil pan and loosely install the 16 bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 3353 5. Tighten the bolts in 3 stages, in the sequence shown. ^ Stage 1: Tighten to 2 Nm (18 inch lbs.). ^ Stage 2: Tighten to 20 Nm (15 ft. lbs.). ^ Stage 3: Tighten an additional 60°. 4WD vehicles 6. CAUTION: Use care when positioning the front axle housing, or the vacuum lines to the axle solenoid may become disconnected or damaged. Position the front axle housing and loosely install the 3 bolts, aligning the bolt location marks made during removal. 7. Install the front axle housing RH mounting bolt. ^ Tighten to 89 Nm (66 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 3354 8. Install the front axle housing LH front mounting bolt. ^ Tighten to 89 Nm (66 ft. lbs.). 9. Install the front axle housing LH rear mounting bolt. ^ Tighten to 89 Nm (66 ft. lbs.). All vehicles 10. Position the frame crossmember and the 4 bolts. ^ Tighten to 102 Nm (75 ft. lbs.). 11. Install the wire harness bracket and the bolt. ^ Tighten to 10 Nm (89 inch lbs.). 12. Fill the crankcase with clean engine oil. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 3358 C103 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair ENGINE OIL PRESSURE (EOP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Disconnect the engine oil pressure (EOP) sensor electrical connector. 4. Remove the EOP sensor. - To install, tighten to 21 Nm (15 lb-ft). 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Service and Repair Oil Pick Up/Strainer: Service and Repair Oil Pump Screen and Pickup Tube Material Removal 1. Remove the oil pan. 2. Remove the 3 bolts and the oil pump screen and pickup tube. Installation 1. CAUTION: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring can cause foam in the lubrication system, low oil pressure and severe engine damage. NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate the O-ring with clean engine oil prior to installation. Position the oil pump screen and pickup tube and install the bolts. ^ Tighten the oil pump screen and pickup tube-to-oil pump bolts to 10 Nm (89 inch lbs.). ^ Tighten the oil pump screen and pickup tube-to-spacer bolt to 25 Nm (18 ft. lbs.). 2. Install the oil pan. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil pressure minimum at 2,000 rpm (engine at normal operating temperature) ............................................................................................ 517 kPa (75 psi) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Sensor/Switch, Engine > Component Information > Description and Operation Oil Temperature Sensor/Switch: Description and Operation ENGINE OIL TEMPERATURE (EOT) SENSOR Typical Engine Oil Temperature (EOT) Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system. The PCM can use the EOT sensor input to determine the following: - On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM begins reducing power by disabling engine cylinders. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications Intake Manifold: Specifications Intake manifold bolts First pass ............................................................................................................................................. .......................................... 2 Nm (18 inch lbs.) Final pass .................................................................. ................................................................................................................... 10 Nm (89 inch lbs.) Throttle body bolts First pass ............................................................................................................................................. .......................................... 9 Nm (80 inch lbs.) Final pass .................................................................. .................................................................................................................................. tighten 90° Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal and Installation Intake Manifold: Service and Repair Removal and Installation Intake Manifold Material Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal and Installation > Page 3377 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal and Installation > Page 3378 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal and Installation > Page 3379 Removal WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury. WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal and Installation > Page 3380 1. Drain the cooling system. For additional information, refer to Cooling System. 2. Disconnect the fuel supply hose spring lock coupling from the fuel rail. For additional information, refer to Fuel Delivery and Air Induction. 3. Remove the generator. For additional information, refer to Alternator. 4. Remove the air cleaner. For additional information, refer to Fuel Delivery and Air Induction. 5. Disconnect the upper radiator hose from the thermostat housing. 6. Disconnect the heater coolant hose from the coolant bypass tube. 7. Disconnect the quick connect coupling and remove the evaporative emissions system (EVAP) tube from the intake manifold. For additional information, refer to Fuel Delivery and Air Induction. 8. Disconnect the quick connect couplings and remove the positive crankcase ventilation (PCV) tube. For additional information, refer to Fuel Delivery and Air Induction. 9. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum connector. 10. Disconnect the 8 fuel injector electrical connectors. 11. Disconnect the throttle position (TP) sensor and electronic acceleration control electrical connectors. 12. Disconnect the heated PCV intake fitting electrical connector. 13. Disconnect the brake booster vacuum hose from the intake manifold vacuum tube. 14. Remove the 10 intake manifold bolts 15. 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. Remove the 3 bolts, the coolant bypass tube and discard the gaskets. ^ Clean and inspect the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. 16. Disconnect the charge motion control valve (CMCV) electrical connector. 17. Disconnect the manifold vacuum tube from the valve cover stud and the support bracket. 18. Disconnect the cylinder head temperature (CHT) sensor jumper harness electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal and Installation > Page 3381 19. Disconnect the LH and RH knock sensor (KS) electrical connectors. 20. Remove the nut and disconnect the engine wiring harness retainer from the CMCV stud. 21. 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. Remove the intake manifold and discard the gaskets. ^ Inspect and clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Installation 1. NOTE: Electrical and vacuum harnesses must not restrict movement of the CMCV control rods at rear of the intake manifold. Use extreme care on installation of the intake manifold to prevent any pinching of electrical and vacuum harnesses. Using new intake manifold gaskets, position the intake manifold. 2. Using new gaskets, position the coolant crossover and install the 3 bolts. ^ Tighten to 10 Nm (89 inch lbs.). 3. Install the intake manifold bolts and tighten in 2 stages, in the sequence shown. ^ Stage 1: Tighten to 2 Nm (18 inch lbs.). ^ Stage 2: Tighten to 10 Nm (89 inch lbs.). 4. Connect the engine wiring harness retainer to the CMCV stud and install the nut. ^ Tighten to 10 Nm (89 inch lbs.). 5. Connect the CMCV electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal and Installation > Page 3382 6. Connect the CHT sensor jumper harness electrical connector. 7. Connect the LH and RH KS electrical connectors. 8. Connect the manifold vacuum tube to the support bracket and the valve cover stud. 9. Connect the brake booster vacuum hose to the intake manifold vacuum tube. 10. Connect the heated PCV intake fitting electrical connector. 11. Connect the TP sensor and electronic acceleration control electrical connectors. 12. Connect the 8 fuel injector electrical connectors. 13. Connect the fuel rail pressure and temperature sensor electrical connector and vacuum connector. 14. Connect the fuel supply spring lock coupling to the fuel rail. For additional information, refer to Fuel Delivery and Air Induction. 15. Position the PCV tube and connect the quick connect couplings. For additional information, refer to Fuel Delivery and Air Induction. 16. Position the EVAP tube and connect the quick connect coupling to the intake manifold. For additional information, refer to Fuel Delivery and Air Induction. 17. Connect the heater coolant hose to the coolant bypass. 18. Connect the upper radiator hose to the thermostat housing. 19. Install the generator. For additional information, refer to Alternator. 20. Install the air cleaner. For additional information, refer to Fuel Delivery and Air Induction. 21. Fill and bleed the engine cooling system. For additional information, refer to Cooling System. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal and Installation > Page 3383 Intake Manifold: Service and Repair Disassembly and Assembly Intake Manifold Assembly Material Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal and Installation > Page 3384 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal and Installation > Page 3385 Special Tool(s) Disassembly 1. Remove the 4 bolts and the throttle body (TB). 2. Remove the 4 bolts and the fuel rail. 3. Remove the fuel injector-to-fuel rail locking clip and separate the fuel injectors from the fuel rail. ^ Discard the 2 O-ring seals from each fuel injector. 4. Remove the vacuum tube assembly from the intake manifold. 5. Remove the charge motion control valve (CMCV) rod locking clips. 6. Remove the stud bolt, the 2 bolts and the CMCV. 7. Remove the 2 bolts and the positive crankcase ventilation (PCV) heater element. ^ Discard the O-ring seal. 8. Remove the engine noise shield insulator from the intake manifold. Assembly 1. Install the engine noise shield insulator onto the intake manifold. 2. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation. Using a new O-ring seal, install the PCV heater element and the 2 bolts. ^ Tighten to 6 Nm (53 inch lbs.). 3. Position the CMCV and install the stud bolt and the 2 bolts. ^ Tighten to 10 Nm (89 inch lbs.). 4. Install the CMCV rod locking clips. 5. Install the vacuum tube assembly onto the intake manifold. 6. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation. Install new O-ring seals on each of the fuel injectors. 7. Assemble the fuel injectors onto the fuel rail and install the locking clips. 8. Install the fuel rail and fuel injector assembly onto the intake manifold. 9. Install the 4 fuel rail bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal and Installation > Page 3386 ^ Tighten to 10 Nm (89 inch lbs.). 10. Install the TB and tighten the bolts in 2 stages. ^ Stage 1: Tighten to 9 Nm (80 inch lbs.). ^ Stage 2: Tighten an additional 90°. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Diagrams Crankshaft Main Bearing Seal: Diagrams Engine - Lower End Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Diagrams > Page 3391 Engine - Lower End Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Diagrams > Page 3392 Engine - Lower End Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Diagrams > Page 3393 Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Seal with Retainer Plate Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Diagrams > Page 3394 Material Removal 1. Remove the transmission. 2. Remove the 8 bolts and the flexplate. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Diagrams > Page 3395 3. Using the special tools, remove the crankshaft oil slinger. ^ Discard the crankshaft oil slinger. 4. Using the special tools, remove the crankshaft rear seal. ^ Discard the crankshaft rear seal. 5. Remove the 2 oil pan-to-crankshaft rear seal retainer plate bolts. 6. Remove the 6 bolts and the crankshaft rear seal retainer plate. Installation 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. NOTE: Clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage. Clean and inspect the mating surface. 2. NOTE: If the rear crankshaft seal retaining plate is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leaks. NOTE: The silicone must be applied on the groove along the retainer plate. Apply a 4.06 mm (0.16 inch) bead of silicone gasket and sealant around the crankshaft rear seal retainer plate sealing surface. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Diagrams > Page 3396 3. Install the crankshaft rear seal retainer plate and the 6 bolts in the sequence shown. ^ Tighten to 10 Nm (89 inch lbs.). 4. Install the 2 crankshaft rear seal retainer plate-to-oil pan bolts and tighten in 2 stages. ^ Stage 1: Tighten to 20 Nm (15 ft. lbs.). ^ Stage 2: Tighten an additional 60°. 5. NOTE: Lubricate the inner lip of the crankshaft rear seal with clean engine oil. Using the special tools, install a new crankshaft rear seal. 6. Using the special tools, install a new crankshaft rear oil slinger. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Diagrams > Page 3397 7. Install the flexplate and tighten the 8 bolts in the sequence shown. ^ Tighten to 80 Nm (59 ft. lbs.). 8. Install the transmission. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Diagrams Front Crankshaft Seal: Diagrams Engine - Front End Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Diagrams > Page 3401 Engine - Front End Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Diagrams > Page 3402 Front Crankshaft Seal: Service and Repair Crankshaft Front Seal Special Tool(s) Material Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Diagrams > Page 3403 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the engine cooling fan lower shroud. For additional information, refer to Cooling System. 3. Rotate the tensioner clockwise and remove the accessory drive belt from the crankshaft pulley. 4. Remove the crankshaft pulley bolt and washer. ^ Discard the crankshaft pulley bolt. 5. Using the special tool, remove the crankshaft pulley. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Diagrams > Page 3404 6. Using the special tool, remove and discard the crankshaft front seal. Installation 1. Lubricate the engine front cover and the new crankshaft front seal inner lip with clean engine oil. 2. Using the special tools, install the new crankshaft front seal. 3. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep and silicone gasket remover. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Diagrams > Page 3405 4. Using the special tool, install the crankshaft pulley. 5. Using a new crankshaft pulley bolt, install the bolt and washer and tighten the bolt in 4 stages. ^ Stage 1: Tighten to 90 Nm (66 ft. lbs.). ^ Stage 2: Loosen 360°. ^ Stage 3: Tighten to 50 Nm (37 ft. lbs.). ^ Stage 4: Tighten an additional 90°. 6. Rotate the tensioner clockwise and install the accessory drive belt onto the crankshaft pulley. 7. Install the engine cooling fan lower shroud. For additional information, refer to Cooling System. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair Valve Guide Seal: Service and Repair Valve Seals Special Tool(s) Material Removal 1. Depending on the valve being serviced, remove the LH or RH valve cover. 2. Remove the spark plug. For additional information, refer to Ignition System. 3. Rotate the crankshaft until the piston for the valve being serviced is at the top of its stroke with the intake valve and the exhaust valves closed. 4. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations. Using the special tool, compress the valve spring and remove the camshaft roller follower. 5. Use compressed air in the cylinder to hold both valves in position. ^ Apply a minimum of 965 kPa (140 psi) of compressed air into the cylinder. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 3409 6. CAUTION: If air pressure has forced the piston to the bottom of the cylinder, any loss of air pressure will allow the valve to fall into the cylinder. If air pressure must be removed, support the valve prior to removal. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for locations. NOTE: If a valve drops into the cylinder, remove the cylinder head. Using the special tool, compress the valve spring and remove the valve spring retainer keys. 7. Remove the valve spring retainer, the valve spring and the valve seal. ^ Discard the valve seal. 8. Inspect the components. Installation 1. NOTE: Lubricate the valve seal and valve stem with clean engine oil prior to installation. Using the special tool, install a new valve seal. 2. Using the special tool, install the valve spring, the valve spring retainer and the valve spring retainer keys. 3. Relieve the air pressure from the cylinder. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 3410 4. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations. NOTE: Lubricate the camshaft roller follower with clean engine oil prior to installation. ^ Using the special tool, compress the valve spring and install the camshaft roller follower. 5. Install the spark plug. For additional information, refer to Ignition System. 6. Depending on the valve being serviced, install the LH or RH valve cover. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 3415 C103 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair ENGINE OIL PRESSURE (EOP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Disconnect the engine oil pressure (EOP) sensor electrical connector. 4. Remove the EOP sensor. - To install, tighten to 21 Nm (15 lb-ft). 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Description and Operation Oil Temperature Sensor/Switch: Description and Operation ENGINE OIL TEMPERATURE (EOT) SENSOR Typical Engine Oil Temperature (EOT) Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system. The PCM can use the EOT sensor input to determine the following: - On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM begins reducing power by disabling engine cylinders. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair Camshaft Gear/Sprocket: Service and Repair Special Tool(s) Removal 1. If servicing the RH camshaft phaser and sprocket, remove the RH camshaft. For additional information, refer to Camshaft - RH. See: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair 2. If servicing the LH camshaft phaser and sprocket, remove the LH camshaft. For additional information, refer to Camshaft - LH. See: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair 3. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the special tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive Components. See: Remove the camshaft phaser and sprocket from the timing chain. 4. Inspect the front of the camshaft phaser and sprocket for missing or damaged roll pins. - If the roll pins are missing or damaged, a new camshaft phaser and sprocket must be installed. 5. Inspect the rear of the camshaft phaser and sprocket for a deformed or damaged location pin. - If the location pin is deformed or damaged, a new camshaft phaser and sprocket must be installed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair > Page 3426 6. Visually inspect the camshaft phaser and sprocket for squareness (A). If the trigger wheel or spring is deformed or damaged (B), install a new camshaft phaser and sprocket. Installation 1. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. If installing a new camshaft phaser and sprocket, transfer the original scribe mark to the new camshaft phaser and sprocket. 2. NOTICE: The timing chain must be installed in its original position onto the camshaft phaser and sprocket using the scribed marks, or damage to valves and pistons will result. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. Align the scribe marks and position the camshaft phaser and sprocket into the timing chain. 3. If servicing the RH camshaft phaser and sprocket, install the RH camshaft. For additional information, refer to Camshaft - RH. See: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair 4. If servicing the LH camshaft phaser and sprocket, install the LH camshaft. For additional information, refer to Camshaft - LH. See: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair Timing Chain: Service and Repair Timing Drive Components Special Tool(s) Material Material Removal 1. Remove the engine front cover. 2. Remove the crankshaft sensor ring from the crankshaft. 3. Position the crankshaft keyway at the 12 o'clock position. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3430 4. NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft will require one full additional rotation to 12 o'clock. The number 1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and the exhaust lobe on the number 1 cylinder. 5. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations. Remove only the 3 roller followers shown in the illustration from the RH cylinder head. 6. CAUTION: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3431 NOTE: It may be necessary to push the valve down while compressing the spring. Using the special tool, remove the 3 designated roller followers in the previous step from the RH cylinder head. 7. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations. Remove only the 3 roller followers shown in the illustration from the LH cylinder head. 8. CAUTION: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3432 NOTE: It may be necessary to push the valve down while compressing the spring. Using the special tool, remove the 3 designated roller followers in the previous step from the LH cylinder head. 9. CAUTION: The crankshaft cannot be moved past the 6 o'clock position once set. Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position. 10. CAUTION: If one or both of the tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner or engine damage may occur. Remove the bolts, the LH timing chain tensioner and tensioner arm. 11. CAUTION: If one or both of the tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner or engine damage may occur. Remove the bolts, the RH timing chain tensioner and tensioner arm. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3433 12. Remove the RH and LH timing chains and the crankshaft sprocket. ^ Remove the RH timing chain from the camshaft sprocket. ^ Remove the RH timing chain from the crankshaft sprocket. ^ Remove the LH timing chain from the camshaft sprocket. ^ Remove the LH timing chain and crankshaft sprocket. 13. NOTE: RH shown, LH similar. Remove the LH and RH timing chain guides. ^ Remove the bolts. ^ Remove both timing chain guides. 14. CAUTION: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3434 CAUTION: Only use hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit. Using the special tool, remove the bolt and the RH camshaft phaser sprocket assembly. ^ Discard the camshaft phaser sprocket bolt. 15. CAUTION: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device. CAUTION: Only use hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit. Using the special tool, remove the bolt and the LH camshaft phaser and sprocket assembly. ^ Discard the camshaft phaser sprocket bolt. 16. CAUTION: Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from sideloading. Remove the 2 bolts and the RH cylinder head camshaft front bearing cap. 17. NOTICE: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Failure to follow these instructions may result in engine damage. Remove the remaining 8 bolts in the sequence shown and remove the RH cylinder head camshaft bearing caps. 18. Clean and inspect the RH camshaft bearing caps. The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3435 19. Remove the RH camshaft. 20. CAUTION: Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from sideloading. Remove the 2 bolts and the LH cylinder head camshaft bearing cap. 21. NOTICE: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Failure to follow these instructions may result in engine damage. Remove the remaining 8 bolts in the sequence shown and remove the LH cylinder head camshaft bearing caps. 22. Clean and inspect the LH camshaft bearing caps. The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material. 23. Remove the LH camshaft. 24. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations. Failure to follow these instructions may result in engine damage. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3436 Remove all of the remaining roller followers from the cylinder heads. Installation 1. Install the LH and RH camshafts. ^ Lubricate the camshaft and camshaft journals with clean engine oil prior to installation. 2. NOTE: LH shown, RH similar. Install the LH and RH camshaft bearing caps in their original locations. ^ Lubricate the camshaft bearing caps with clean engine oil. ^ Position the front camshaft bearing cap. ^ Position the remaining camshaft bearing caps. ^ Install the bolts loosely. ^ Tighten to 10 Nm (89 inch lbs.). in the sequence shown. 3. CAUTION: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTE: LH shown, RH similar. Install the camshaft phaser sprockets and new camshaft phaser bolts finger tight. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3437 4. CAUTION: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device. CAUTION: Only use hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit. NOTE: LH shown, RH similar. Using the special tool, tighten the LH and RH camshaft phaser sprocket bolts in 2 stages. ^ Stage 1: Tighten to 40 Nm (30 ft. lbs.). ^ Stage 2: Tighten an additional 90 degrees. 5. Using the special tool, position the crankshaft keyway at the 11 o'clock position. 6. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result. CAUTION: Prior to installation, inspect the tensioner-sealing bead for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner. Compress the tensioner plunger, using a vise. 7. Install a retaining clip on the tensioner to hold the plunger in during installation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3438 8. Remove the tensioner from the vise. 9. If the copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks. 10. Install the crankshaft sprocket, making sure the flange faces forward. 11. Install the 4 bolts and the LH and RH timing chain guides. ^ Tighten to 10 Nm (89 inch lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3439 12. Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain. 13. NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel. Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the two copper (marked) chain links. 14. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and bolts. ^ Tighten to 25 Nm (18 ft. lbs.). 15. Remove the retaining clip from the LH timing chain tensioner. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3440 16. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) chain link. 17. NOTE: The lower half of the timing chain must be positioned above the tensioner arm dowel. NOTE:The camshaft phaser and sprocket will be stamped with one of the illustrated timing marks for the RH camshaft. Position the RH timing chain on the camshaft phaser and sprocket wil the timing mark positioned between the 2 copper (marked) chain links. 18. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and bolts. ^ Tighten to 25 Nm (18 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3441 19. Remove the retaining clip from the RH timing chain tensioner. 20. As a post-check, verify correct alignment of all timing marks. 21. Install the crankshaft sensor ring on the crankshaft. 22. NOTICE: If the components are to be reinstalled, they must be installed into their original locations. Failure to follow these instructions may result in engine damage. NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valave drops into the cylinder, the cylinder head must be removed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 3442 NOTE: It may be necessary to push the valve down while compressing the spring. Using the speical tool, install all of the camshaft roller followers. Lubricate the roller followers with clean engine oil prior to installation. 23. Install the engine front cover. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications Timing Chain Tensioner: Specifications timing chain tensioner and bolts .......................................................................................................... ..................................................... 25 Nm (18 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Timing cover front bolts & nuts Fasteners 1 through 15 ....................................................................................................................... ............................................. 25 Nm (18 ft. lbs.) Fasteners 6 & 7 ........................................................ ....................................................................................................................... 48 Nm (35 ft. lbs.) Timing cover lower bolts First pass ............................................................................................................................................. ............................................ 20 Nm (15 ft. lbs.) Final pass .................................................................. .............................................................................................................................................. 60° Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3449 Timing Cover: Service and Repair Engine Front Cover Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3450 Material Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3451 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3452 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Drain the engine oil. 3. Remove the engine cooling fan. For additional information, refer to Cooling System. 4. Remove the RH valve cover. 5. Remove the LH valve cover. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3453 6. Rotate the tensioner clockwise and remove the accessory drive belt. 7. Remove the nut and the power steering pressure hose support bracket. 8. Remove the nut and the transmission cooler tube support bracket. 9. Remove the crankshaft pulley bolt and washer. ^ Discard the crankshaft pulley bolt. 10. Using the special tool, remove the crankshaft pulley. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3454 11. Using the special tool, remove and discard the crankshaft front seal. 12. Remove the 3 bolts and the 3 accessory drive idler pulleys. 13. Remove the 4 bolts and the coolant pump pulley. 14. Remove the 3 bolts and the accessory drive belt tensioner. 15. Disconnect the RH camshaft position (CMP) sensor electrical connector. 16. Remove the bolt and the RH CMP sensor. ^ Discard the O-ring seal. 17. NOTE: LH shown, RH similar. Disconnect the radio ignition interference capacitor electrical connectors. 18. Remove the nut and the RH radio ignition interference capacitor. 19. Disconnect the LH CMP sensor electrical connector. 20. Remove the bolt and the LH CMP sensor. ^ Discard the O-ring seal. 21. Remove the nut and the LH radio ignition interference capacitor. 22. Remove the bolts and position the power steering pump assembly aside. 23. Disconnect the crankshaft position (CKP) sensor electrical connector. 24. Remove the 4 front oil pan bolts. 25. Remove the bolts and the studs. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3455 26. Remove the engine front cover from the front cover to cylinder block dowel. 27. Remove the bolt and the CKP sensor. ^ Discard the O-ring seal. 28. 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. Remove and discard the engine front cover gaskets. ^ Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. ^ Inspect the mating surfaces. Installation 1. Install the CKP sensor and the bolt. ^ Tighten to 10 Nm (89 inch lbs.). 2. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3456 3. Install new engine front cover gaskets on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger tight. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3457 4. Tighten the engine front cover fasteners in 2 stages, in the sequence shown. ^ Stage 1: Tighten fasteners 1 through 15 to 25 Nm (18 ft. lbs.). ^ Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 ft. lbs.). 5. Loosely install the bolts, then tighten the bolts in 2 stages, in the sequence shown. ^ Stage 1: Tighten to 20 Nm (15 ft. lbs.). ^ Stage 2: Tighten an additional 60°. 6. Connect the CKP sensor electrical connector. 7. Position the power steering pump assembly and install the bolts. ^ Tighten to 25 Nm (18 ft. lbs.). 8. Position the power steering pressure hose support bracket and install the nut. ^ Tighten to 10 Nm (89 inch lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3458 9. Position the transmission cooler tube support bracket and install the nut. ^ Tighten to 10 Nm (89 inch lbs.). 10. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation. Using a new O-ring seal, install the RH CMP sensor and the bolt. ^ Tighten to 10 Nm (89 inch lbs.). 11. Connect the RH CMP sensor electrical connector. 12. Install the LH radio ignition interference capacitor and the nut. ^ Tighten to 10 Nm (89 inch lbs.). 13. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation. Using a new O-ring seal, install the LH CMP sensor and the bolt. ^ Tighten to 10 Nm (89 inch lbs.). 14. Connect the LH CMP sensor electrical connector. 15. Install the RH radio ignition interference capacitor and the nut. ^ Tighten to 10 Nm (89 inch lbs.). 16. NOTE: LH shown, RH similar. Connect the radio ignition interference capacitor electrical connectors. 17. Install the accessory drive belt tensioner and the 3 bolts. ^ Tighten to 25 Nm (18 ft. lbs.). 18. Install the coolant pump pulley and the 4 bolts. ^ Tighten to 25 Nm (18 ft. lbs.). 19. Install the 3 accessory drive idler pulleys and the 3 bolts. ^ Tighten to 25 Nm (18 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3459 20. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil. 21. Using the special tools, install the crankshaft front seal into the engine front cover. 22. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley. 23. Use the special tool to install the crankshaft pulley. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3460 24. Tighten the new crankshaft pulley bolt in 4 stages. ^ Stage 1: Tighten to 90 Nm (66 ft. lbs.). ^ Stage 2: Loosen 360°. ^ Stage 3: Tighten to 50 Nm (37 ft. lbs.). ^ Stage 4: Tighten an additional 90°. 25. Rotate the tensioner clockwise and install the accessory drive belt. 26. Install the RH valve cover. 27. Install the LH valve cover. 28. Install the engine cooling fan. For additional information, refer to Cooling System. 29. Fill the crankcase with clean engine oil. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 C1451 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 > Page 3466 C1452 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Page 3467 Variable Valve Timing Actuator: Description and Operation VARIABLE CAMSHAFT TIMING (VCT) SYSTEM Overview The VCT enables rotation of the camshaft(s) relative to the crankshaft rotation as a function of engine operating conditions. There are 4 types of VCT systems. Exhaust phase shifting (EPS) system - the exhaust cam is the active cam being retarded. - Intake phase shifting (IPS) system - the intake cam is the active cam being advanced. - Dual equal phase shifting (DEPS) system - both intake and exhaust cams are phase shifted and equally advanced or retarded. - Dual independent phase shifting (DIPS) system - where both the intake and exhaust cams are shifted independently. All systems have 4 operational modes: idle, part throttle, wide open throttle (WOT), and default mode. At idle and low engine speeds with closed throttle, the powertrain control module (PCM) determines the phase angle based on air flow, engine oil temperature and engine coolant temperature. At part and wide open throttle the PCM determines the phase angle based on engine RPM, load, and throttle position. VCT systems provide reduced emissions and enhanced engine power, fuel economy and idle quality. IPS Systems also have the added benefit of improved torque. In addition, some VCT system applications can eliminate the need for an external exhaust gas recirculation (EGR) system. The elimination of the EGR system is accomplished by controlling the overlap time between the intake valve opening and exhaust valve closing. Currently, both the IPS and DEPS systems are used Variable Camshaft Timing (VCT) System Variable Camshaft Timing System The VCT system consists of an electric hydraulic positioning control solenoid, a camshaft position (CMP) sensor, and a trigger wheel. The CMP trigger wheel has a number of equally spaced teeth equal to the number (n) of cylinders on a bank plus one extra tooth (n+1). Four cylinder and V8 engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1 tooth trigger wheel. The extra tooth placed between the equally spaced teeth represents the CMP signal for that bank. A crankshaft position sensor (CKP) provides the PCM with crankshaft positioning information in 10 degree increments. 1. The PCM receives input signals from the intake air temperature (IAT) sensor, engine coolant temperature (ECT) sensor, engine oil temperature (EOT) sensor, CMP, throttle position (TP) sensor, mass air flow (MAF) sensor, and CKP to determine the operating conditions of the engine. At idle and low engine speeds with closed throttle, the PCM controls the camshaft position based on ECT, EOT, IAT, and MAF. During part and wide open throttle, the camshaft position is determined by engine RPM, load and throttle position. The VCT system does not operate until the engine is at normal operating temperature. 2. The VCT system is enabled by the PCM when the correct conditions are met. 3. The CKP signal is used as a reference for CMP positioning. 4. The VCT solenoid valve is an integral part of the VCT system. The solenoid valve controls the flow of engine oil in the VCT actuator assembly. As the PCM controls the duty cycle of the solenoid valve, oil pressure/flow advances or retards the cam timing. Duty cycles near 0% or 100% represent rapid movement of the camshaft. Retaining a fixed camshaft position is accomplished by dithering (oscillating) the solenoid valve duty cycle. The PCM calculates and determines the desired camshaft position. It continually updates the VCT solenoid duty cycle until the desired position is Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Page 3468 achieved. A difference between the desired and actual camshaft position represents a position error in the PCM VCT control loop. The PCM disables the VCT and places the camshaft in a default position if a concern is detected. A related DTC is also set when the concern is detected. 5. When the VCT solenoid is energized, engine oil is allowed to flow to the VCT actuator assembly which advances or retards the camshaft timing. One half of the VCT actuator is coupled to the camshaft and the other half is connected to the timing chain. Oil chambers between the 2 halves couple the camshaft to the timing chain. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the camshaft to rotate in either an advance or retard position depending on the oil flow. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Service and Repair Variable Valve Timing Solenoid: Service and Repair VARIABLE CAMSHAFT TIMING OIL CONTROL SOLENOID LH Shown, RH Similar. Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the variable camshaft timing (VCT) oil control solenoid electrical connector. 3. Remove the VCT oil control solenoid grommet. 4. Remove the bolt and the VCT oil control solenoid. Discard the O-ring seal. - To install, tighten to 5 Nm (44 lb-in). - Install a new O-ring seal. Lubricate the new O-ring seal with clean engine oil prior to installation. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Item....................................................................................................................................................... ..............................................................Specification Fuel Pressure Key on, engine off................................................................................................................................. .............................................240-310 kPa (35-45 psi) Engine running................................................. ..................................................................................................................................193-310 kPa (28-45 psi) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Measured/PID Values Hot Idle Speed ..................................................................................................................................... ....................................................... 600-650 RPM Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 AIR CLEANER INTAKE PIPE Exploded View Removal and Installation 1. Remove the air cleaner element. 2. Reach into the opening of the air cleaner assembly and depress the locking tab on the air cleaner intake pipe to release the air cleaner intake pipe from the air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3483 3. Remove the air cleaner intake tube assembly. 4. CAUTION: The air cleaner intake pipe should be securely sealed to prevent unusual engine noise. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair AIR CLEANER ELEMENT Exploded View Removal and Installation 1. Release the retaining clips and remove the air cleaner element tray. 2. Remove the air cleaner element from the air cleaner element tray. 3. CAUTION: The air cleaner element tray must be fully seated to the air cleaner housing. Failure to do so will result in unusual engine noise. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The electrical connector is located on the LH frame rail under the driver side door. Disconnect the electrical connector. 3. Start the engine and allow it to idle until it stalls. 4. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail pressure has been released. 5. Turn the ignition switch to the OFF position. 6. When fuel system service is complete, connect the electrical connector. 7. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 8. Install the diagnostic tool. Turn the key ON with the engine OFF. Cycle the key OFF, then ON. Select the appropriate vehicle and engine qualifier. Clear all diagnostic trouble codes (DTCs) and carry out a PCM reset. 9. Start the vehicle and check the fuel system for leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Firing order........................................................................................................................................... ......................................................... 1-3-7-2-6-5-4-8 Eight separate ignition coils: - are mounted directly above each spark plug. - are controlled by the powertrain control module (PCM) for correct firing sequence. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 Item ...................................................................................................................................................... ............................................................ Specification Firing order........................................................................................................................................... ......................................................... 1-3-7-2-6-5-4-8 Eight separate ignition coils: - are mounted directly above each spark plug. - are controlled by the powertrain control module (PCM) for correct firing sequence. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions Spark Plug: Technical Service Bulletins Ignition System - Spark Plug Removal Instructions TSB 08-7-6 04/14/08 SPARK PLUG REMOVAL INSTRUCTIONS - 4.6L 3V/5.4L 3V16.8L 3V FORD: 2005-2008 Mustang 2004-2008 F-150 2005-2008 Expedition, F-Super Duty 2006-2008 Explorer, F-53 Motorhome Chassis 2007-2008 Explorer Sport Trac LINCOLN: 2005-2008 Navigator 2006-2008 Mark LT MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-1-9 to update Vehicle Applications, Service Procedure and Part List. ISSUE Some 2004-2008 F-150, 2006-2008 Mark LT, 2005-2008 F-Super Duty, Expedition, and Navigator, with 5.4L 3-V engine; 2005-2008 Mustang, 2006-2008 Explorer, Mountaineer, and 2007-2008 Explorer Sport Trac with 4.6L 3-V engine; 2005-2008 F-Super Duty, 2006-2008 and F-Stripped Chassis, with 6.8L 3-V engine may experience difficulty with spark plug removal. This may cause damage to the spark plug and leave part of the spark plug in the cylinder head. Affected engine build dates are as follows: 5.4L 3-V and 6.8L 3-V before 10/9/07, 4.6L 3-V before 11/30/07. ACTION Refer to the following Service Procedure for techniques to remove the spark plugs and extract broken spark plugs. SERVICE PROCEDURE The engine build date can be read on the left hand cam cover information sticker. To remove spark plugs without damage, it is necessary to adhere exactly to this procedure before removal is attempted. CAUTION DO NOT REMOVE PLUGS WHEN THE ENGINE IS WARM OR HOT. THE ENGINE MUST BE AT ROOM TEMPERATURE WHEN PERFORMING SPARK PLUG SERVICE. REMOVING THE SPARK PLUGS FROM A WARM/HOT ENGINE INCREASES THE CHANCE THE THREADS COULD BE DAMAGED. Spark Plug Removal Procedure 1. Remove the coil-on-plug assemblies and thoroughly blow out the spark plug wells and surrounding valve cover area with compressed air. 2. Back out the spark plugs no more than 1/8 to 1/4 of a turn. Using Motorcraft(R) Carburetor Tune-Up Cleaner, fill the spark plug well just above where the jamb nut hex sits (1/2 - 3/4 teaspoon). A minimum period of 15 minutes of soak time is required. The cleaner will wick down to the ground electrode shield and soften the carbon deposits in this time. DO NOT WORK the spark plug back and forth at this point. NOTE COMPLETELY REVIEW THE PRODUCT LABEL FOR THE MOTORCRAFT CARBURETOR TUNE-UP CLEANER PRODUCT - USE AT ROOM TEMPERATURE AND SHAKE WELL. CAUTION EXCESSIVE MOTORCRAFT(R) CARBURETOR TUNE-UP CLEANER, OR REPEATING THE PROCESS SEVERAL TIMES WITH TOO MUCH CLEANER FLUID, COULD INTRODUCE ENOUGH LIQUID VOLUME TO HYDRO-LOCK THE ENGINE. CAUTION DO NOT USE AIR OR POWER TOOLS FOR SPARK PLUG REMOVAL. SPARK PLUGS MUST ONLY BE REMOVED WITH HAND TOOLS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3502 3. Tighten, and then loosen the spark plug, working the plug back and forth. Some screeching and high effort may be noticed. The expected removal torque is about 33 lb-ft (45 N.m). Repeat the back and forth turning as needed until turning effort is reduced, and remove the spark plugs. NOTE NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT HIGH TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD. DO NOT COAT THE ELECTRODE STRAP. (Figure 1) Separated/Broken Spark Plug Removal If the spark plug separates after following the Spark Plug Removal Procedure, it will fail in one of three modes. Refer to the appropriate removal procedure as required. a. Mode 1: The ground electrode shield is left behind as an empty shell. (Figure 2) b. Mode 2: The entire porcelain insulator and ground electrode shield remains in the cylinder head. (Figure 3) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3503 c. Mode 3: The upper section of porcelain broke off with remaining porcelain left inside the ground shield. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3504 Flowchart of procedure. (Figure 5) Mode 1 Procedure: Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3505 Use Rotunda special service tool 303-1203 to remove an empty ground electrode shield from the cylinder head. (Figure 6) NOTE THIS TOOL IS ONLY DESIGNED TO WORK WITH AN EMPTY GROUND ELECTRODE SHIELD. IF PORCELAIN REMAINS, PROCEED TO MODE 2 OR 3 REMOVAL. 1. Modify vacuum cap to a 3/8" (10 mm) length for each ground electrode shield that needs to be removed. (Figure 7) 2. Use the installation rod (J) provided with service tool 303-1203 update to install the modified vacuum cap. Push the cap into the ground shield down to the electrode strap. This will plug and protect the combustion chamber from contamination. (Figure 7) 3. Thread-tap the ground electrode shield using a 9.0 x 1.0 mm plug tap (tap profile is about 3-4 reduced diameter threads on the tip end). a. Coat the end of the tap with general purpose grease. (Figure 8) b. Turn the tap about 3 to 4 turns into the ground electrode shield. Back the tap up frequently to break chips and avoid cut material from coiling-up in the spark plug well. A tap socket adaptor (K) is provided with service tool 303-1203 update to connect the tap to a 3/8" socket Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3506 drive. CAUTION DO NOT ATTEMPT TO REMOVE THE GROUND ELECTRODE SHIELD WITH THE TAP AND WRENCH. THE TAP MAY BREAK IF THIS IS ATTEMPTED. 4. Thread Rotunda special service tool 303-1203 into the ground electrode shield. (Figure 9) a. Install the stepped end of the tool pilot bushing into the spark plug well ensuring it bottoms out. b. Screw the center shank into the ground electrode shield. Do not over tighten the shank, to prevent thread stripping. c. Install the nylon washer and jack nut until finger tight. d. Turn the jack nut until the ground electrode is freed from the cavity and withdraw the tool assembly. NOTE NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD. DO NOT COAT THE ELECTRODE STRAP. Mode 2 Procedure: 1. Add an additional 1/2 teaspoon Motorcraft® Carburetor Tune-Up Cleaner fluid into spark plug well and allow 15 minutes of soak time. 2. Using long-reach nose pliers grasp and remove the porcelain with an up and down motion taking care not to fracture the porcelain. 3. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder head. Mode 3 Procedure: CAUTION DO NOT DRIVE PORCELAIN DOWN INTO THE GROUND SHIELD WITH A PUNCH AS FRAGMENTS MAY ENTER THE COMBUSTION CHAMBER. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3507 Use Rotunda special service tool kit 303-1398 to remove porcelain broken inside the ground electrode shield. (FIGURE 10) Porcelain Removal - Preparation CAUTION THE ENGINE AND THE BONDING ADHESIVE MUST BE ROOM TEMPERATURE OF 70 °F (21 °C) OR HIGHER FOR PROPER CURE AND BOND STRENGTH. VERIFY EXPIRATION DATE OF ADHESIVE. CAUTION DO NOT REUSE PINS. THIS ENSURES THE CORRECT SURFACE CHARACTERISTICS FOR BONDING. 1. Remove any remaining electrode material from broken porcelain with long nose reach pliers. 2. Spray Motorcraft® Metal Brake Parts Cleaner into the porcelain hole for 2-4 seconds using the straw nozzle supplied with the brake cleaner can. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3508 3. Insert a pin (A) into the collet (B). Screw the collet onto the threaded rod (C). Install the assembled collet, pin, and threaded rod into the steel tool pilot (F). (Figures 11 and 12) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3509 4. Retract the collet and pin into the steel tool pilot, protecting the pin. (Figures 13 and 14) NOTE PIN TIP DAMAGE OR BENT PINS WILL PREVENT INSERTION INTO THE PORCELAIN. 5. Insert the completed assembly into the spark plug well and fully engage the pin into the porcelain. (Figure 15) 6. Spray Motorcraft(R) Metal Brake Parts Cleaner 2-4 seconds between the spark plug well and steel tool pilot. The steel tool pilot must be lifted up approximately 1/2" to allow brake cleaner to flood the porcelain and pin. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3510 7. Scrub the porcelain inside diameter by moving the threaded rod up and down vigorously. Take care making sure the pin does not disengage the porcelain. (Figure 16). 8. Repeat Steps 6 and 7. 9. Remove the tool assembly. Again flood the porcelain with Motorcraft(R) Metal Brake Parts Cleaner for 2-4 seconds, then blow out the entire spark plug well and porcelain with dry compressed air. NOTE CLEAN AND DRY COMPONENTS ARE KEY TO BONDING THE PIN TO THE PORCELAIN. 10. Repeat Steps 1-9 to prepare remaining porcelain fragments as needed. 11. Disassemble the collet and pin from the threaded rod. Dry the tools thoroughly with dry compressed air. Porcelain Removal - Bonding Process CAUTION USE CARE TO PREVENT BONDING AGENT FROM CONTACTING THREADS IN CYLINDER HEAD. NOTE WORKING TIME LIMIT OF LOCTITE(R) 638(TM) RETAINING COMPOUND IS 5 MINUTES. 1. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to opposite sides of a clean and dry applicator (H). Excessive amounts of Loctite(R) 638(TM) are being used if it drips off the applicator. (Figure 17) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3511 2. Insert applicator into the porcelain and move applicator up and down 1/2" (13 mm) while turning to spread the Loctite® 638TM on the inside of the porcelain. (Figure 18). 3. Add additional Loctite(R) 638(TM), repeating Steps 1 and 2. 4. Clean the applicator with Motorcraft(R) Metal Brake Parts Cleaner before the bonding agent starts to cure. 5. Reassemble a dry and clean collet and pin assembly. 6. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to the pin. Excessive amounts of Loctite® 638TMare being used if it drips off the pin. 7. Retract the collet and pin into the steel tool pilot to protect the Loctite(R) 638(TM) coated pin. 8. Insert the completed assembly into spark plug well and fully engage the pin into the porcelain with a twisting motion to spread the bonding agent. 9. Add additional Loctite® 638TM, repeating Steps 6-8. 10. Leave the pin fully inserted in the porcelain while the adhesive cures. Replace the steel tool pilot with the aluminum alignment sleeve (G), Figure 9, to support the threaded rod while the adhesive cures if additional porcelain fragments are present in other cylinders. (Figure 19). CAUTION A MINIMUM 1 HOUR CURING TIME AT 70 °F (21 °C) DEGREES IS REQUIRED BEFORE EXTRACTION IS ATTEMPTED. 11. Allow the Loctite(R) 638(TM) to cure for a minimum of one hour at 70 °F (21 °C). 12. Repeat the bonding process for remaining cylinders as needed. Porcelain Removal - Extraction 1. After a minimum of one hour curing at 70 °F (21 °C), install the steel pilot tool over the threaded rod. 2. Install the washer and jack nut until finger tight against the tool pilot bushing. CAUTION ONLY THE STEEL PILOT TOOL IS ACCEPTABLE FOR USE IN PORCELAIN REMOVAL. 3. While holding the end of the threaded rod with a wrench, tighten the jack nut until the porcelain is free of the ground electrode. 4. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder head. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3512 NOTE NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD. DO NOT COAT THE ELECTRODE STRAP. (FIGURE 7) Porcelain Removal - Pin Slipped Out In the unlikely event that the pin does not remove the broken porcelain, this process can be repeated. Key elements to success are: ^ Clean and dry porcelain ^ Sufficient Loctite® 638TM Retaining Compound spread uniformly ^ Loctite(R) 638(TM) cure time and temperature ^ Preventing the threaded rod from rotating while removing the porcelain Replacement Supplies Replacement kit components and additional kit consumables (Loctite(R) 638TM Retaining Compound and pins) can be obtained by calling 1-800-ROTUNDA, Option 5. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT080706 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 12405 01 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark Plug Gap Spark Plug Gap ............................................................................................................................................................. 0.040 - 0.050 inch (1.02 - 1.27 mm) NOTE: Spark plug gap not adjustable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 3515 Spark Plug: Specifications Spark Plug Torque Spark Plugs ......................................................................................................................................... ................................................... 34 Nm (25.0 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3516 Spark Plug: Application and ID Spark Plug ........................................................................................................................................... ...................................................................... PZT-2F Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3517 Spark Plug: Service and Repair SPARK PLUGS Engine Ignition - RH Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3518 Engine Ignition - LH Exploded View Removal and Installation 1. Remove the ignition coil-on-plug. 2. NOTE: - Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs. - If an original spark plug is used, make sure it is installed in the same cylinder from which it was taken. New spark plugs can be used in any cylinder. Remove the spark plugs. To install, tighten to 34 Nm (25 lb-ft). 3. Inspect the spark plugs. Install new spark plugs as necessary. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications GENERAL SPECIFICATIONS Compression Pressure Limit Chart (Part 1) Compression Pressure Limit Chart (Part 2) The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3522 Compression Check: Testing and Inspection Compression Test-Compression Gauge Check 1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the battery is correctly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of 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 The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart (Part 1) Compression Pressure Limit Chart (Part 2) Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3523 Compression Test-Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications This engine is equipped with hydraulic valve lifters. No adjustment is required. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Water pump bolts ................................................................................................................................ ..................................................... 25 Nm (18 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 3530 Water Pump: Service and Repair Coolant Pump Material Removal and Installation 1. Drain the engine cooling system. 2. Remove the cooling fan. 3. Loosen the 4 coolant pump pulley bolts. ^ To install, tighten to 25 Nm (18 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 3531 4. Rotate the belt tensioner clockwise and disconnect the accessory drive belt from the coolant pump pulley. 5. Remove the 4 bolts and the coolant pump pulley. 6. Remove the 4 bolts and the coolant pump. ^ Discard the O-ring seal. ^ To install, tighten to 25 Nm (18 ft. lbs.). 7. To install, reverse the removal procedure. ^ Inspect the mating surfaces. Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging. ^ Install a new O-ring seal. Lubricate the O-ring seal with clean engine coolant prior to installation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component Information > Service and Repair Thermostat Bypass Hose: Service and Repair Bypass Tube Material Removal and Installation 1. Drain the engine cooling system. 2. Remove the intake manifold. 3. Remove the 3 bolts, the bypass tube, and discard the bypass tube gaskets. ^ To install, tighten to 10 Nm (89 inch lbs.). 4. To install, reverse the removal procedure. ^ Inspect the mating surfaces and clean the sealing surfaces with metal surface prep and silicone gasket remover. Follow the directions on the packaging. ^ Install new bypass tube gaskets. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications COOLING SYSTEM BASE RADIATOR With aux rear heat ............................................................................................................................... ........................................ 20.7 quarts (19.6 liters) Without aux rear heat ........................................... ....................................................................................................................... 19.4 quarts (18.4 liters) HEAVY DUTY TRAILER TOW RADIATOR With aux rear heat ............................................................................................................................... ........................................ 20.9 quarts (19.8 liters) Without aux rear heat ........................................... ....................................................................................................................... 19.7 quarts (18.6 liters) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 3540 Coolant: Fluid Type Specifications ENGINE COOLANT Motorcraft Premium Gold Engine Coolant (yellow-colored) Ford P/N ............................................................................................................................................................ VC-7-A (U.S., except CA, OR and NM) Ford P/N ............................................................................... .................................................................................................. VC-7-B (CA, OR and NM) Ford Specification ................................................................................................................................ ................................................ WSS-M97B51-A1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair Coolant Reservoir: Service and Repair Degas Bottle Material Removal and Installation 1. Drain the engine cooling system. 2. Disconnect the 2 coolant hoses from the degas bottle. 3. Remove the 2 bolts and the degas bottle. ^ To install, tighten to 9 Nm (80 inch lbs.). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Description and Operation Radiator Cooling Fan Motor: Description and Operation FAN CONTROL The PCM monitors certain parameters (such as engine coolant temperature, vehicle speed, A/C on/off status, A/C pressure) to determine engine cooling fan needs. For variable speed electric fan(s): Five Hundred/Freestyle/Montego, Fusion/Milan/Zephyr, Crown Victoria/Grand Marquis, Town Car: FCV Duty Cycle Output From PCM (negative Duty Cycle) LS: FCV Duty Cycle Output From PCM The PCM controls the fan speed and operation using a duty cycle output on the fan control variable (FCV) circuit. The fan controller (located at or integral to the engine cooling fan assembly) receives the FCV command and operates the cooling fan at the speed requested (by varying the power applied to the fan motor). For relay controlled fans: Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Description and Operation > Page 3548 2.0L Focus (with A/C) And Taurus: PCM FC Output State For Cooling Fan Speeds 2.3L Escape: PCM FC Output State For Cooling Fan Speeds Freestar, Monterey: PCM FC Output State For Cooling Fan Speeds The PCM controls the fan operation through the fan control (FC) (single speed fan applications), low fan control (LFC), medium fan control (MFC), and/or high fan control (HFC) outputs. Some applications will have the xFC circuit wired to 2 separate relays. For 3-speed fans, although the PCM output circuits are called low, medium, and high fan control (FC), cooling fan speed is controlled by a combination of these outputs. Refer to the table. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Speed Sensor > Component Information > Description and Operation Radiator Cooling Fan Speed Sensor: Description and Operation FAN SPEED SENSOR (FSS) Cooling Fan Clutch With Fan Speed Sensor (FSS) The FSS is a Hall-effect sensor that measures the cooling fan clutch speed by generating a waveform with a frequency proportional to the fan speed. If the cooling fan clutch is moving at a relatively low speed, the sensor produces a signal with a low frequency. As the cooling fan clutch speed increases, the sensor generates a signal with a higher frequency. The powertrain control module (PCM) uses the frequency signal generated by the FSS as a feedback for closed loop control of the cooling fan clutch. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Service and Repair > Removal and Installation Fan Blade: Service and Repair Removal and Installation Cooling Fan - Blade, Clutch and Shroud Special Tool(s) Removal and Installation 1. Remove the air cleaner inlet pipe and resonator. For additional information, refer to Fuel Delivery and Air Induction. 2. Remove the retainers and the radiator sight shield. 3. Remove the 2 bolts and the lower cooling fan shroud. ^ To install, tighten to 3 Nm (27 inch lbs.). 4. Remove the 2 bolts and the upper cooling fan shroud. ^ To install, tighten to 3 Nm (27 inch lbs.). 5. Using the special tools, remove the cooling fan assembly. ^ To install, tighten to 55 Nm (41 ft. lbs.). 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Service and Repair > Removal and Installation > Page 3556 Fan Blade: Service and Repair Disassembly and Assembly Cooling Fan and Fan Clutch Disassembly and Assembly 1. Remove the 4 cooling fan-to-cooling fan clutch bolts and separate the clutch from the cooling fan. ^ To assemble, tighten to 17 Nm (13 ft. lbs.). 2. To assemble, reverse the disassembly procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Description and Operation Fan Clutch: Description and Operation COOLING FAN CLUTCH Cooling Fan Clutch With Fan Speed Sensor (FSS) The cooling fan clutch is an electrically actuated viscous clutch that consists of 3 main elements: - a working chamber - a reservoir chamber - a cooling fan clutch actuator valve and a fan speed sensor (FSS) The cooling fan clutch actuator valve controls the fluid flow from the reservoir into the working chamber. Once viscous fluid is in the working chamber, shearing of the fluid results in fan rotation. The cooling fan clutch actuator valve is activated with a pulse width modulated (PWM) output signal from the powertrain control module (PCM). By opening and closing the fluid port valve, the PCM can control the cooling fan clutch speed. The cooling fan clutch speed is measured by a Hall-effect sensor and is monitored by the PCM during closed loop operation. The PCM optimizes fan speed based on engine coolant temperature (ECT), engine oil temperature (EOT), transmission fluid temperature (TFT), intake air temperature (IAT), or air conditioning requirements. When an increased demand for fan speed is requested for vehicle cooling, the PCM monitors the fan speed through the Hall-effect sensor. If a fan speed increase is required, the PCM outputs the PWM signal to the fluid port, providing the required fan speed increase. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Description and Operation > Page 3560 Fan Clutch: Testing and Inspection Fan Clutch Test 1. Spin the fan blade by hand. A light resistance should be felt. If there is no resistance or very high resistance, the minimum and maximum fan speeds must be checked as follows: Fan Clutch Test - Minimum Speed Requirement 1. Use a suitable marker to mark the coolant pump pulley, one of the fan blade retaining bolts and the crankshaft pulley. 2. Connect a tachometer to the engine. 3. Install a throttle adjusting tool. 4. Connect a digital photoelectric tachometer. 5. WARNING: To avoid the possibility of personal injury or damage to the vehicle, do not operate the engine until the fan blade has been first examined for possible cracks and separation. Start the engine and run it at approximately 1,500 rpm until the normal operating temperature has been achieved. The A/C must be off. 6. Adjust the engine speed to 2,300 rpm. 7. Operate the digital photoelectric tachometer at 3,000 rpm and aim it at the coolant pump pulley. Adjust the engine speed until the light flash and the coolant pump pulley mark are synchronized. 8. Aim the digital photoelectric tachometer at the fan blade bolts. Adjust the strobe light until the light flash is synchronized with the marked fan blade bolt (the fan blade appears to stand still). 9. The fan blade speed must not be greater than 1,500 rpm at 3,000 coolant pump rpm. 10. Turn the engine off. 11. If the fan blade speed was greater than 1,500 rpm, install a new fan clutch. Fan Clutch Test - Maximum Speed Requirement 1. Carry out Steps 1 through 5 of the Fan Clutch Test-Minimum Speed Requirement. 2. NOTE: The temperature of air in front of the clutch should be above 96°C (205°F) for maximum fan speed. Block off areas on each side of the radiator in the engine compartment and the front of the radiator grille. This will raise the temperature of the air striking the fan clutch and should cause the fan blade to operate at maximum speed. 3. On the electronic manual temperature control (EMTC), select panel mode, with A/C and recirculation buttons requested ON. On the electronic automatic temperature control (EATC), select panel mode, with A/C and recirculation buttons ON and the blower motor switch in the HI position. 4. Adjust the strobe to 3,000 rpm. 5. WARNING: To avoid the possibility of personal injury or damage to the vehicle, do not operate the engine until the fan blade has been first examined for possible cracks and separation. Start the engine and adjust the engine speed until the digital photoelectric tachometer light and the water pump pulley mark are synchronized. 6. Aim the digital photoelectric tachometer light at the fan blade retaining bolts. Adjust the digital photoelectric tachometer light until the light flash is synchronized with the marked fan blade bolt (the fan blade appears to stand still). 7. If the fan blade speed is less than 2,300 rpm, install a new fan clutch. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Service and Repair > Removal and Installation Fan Clutch: Service and Repair Removal and Installation Cooling Fan - Blade, Clutch and Shroud Special Tool(s) Removal and Installation 1. Remove the air cleaner inlet pipe and resonator. For additional information, refer to Fuel Delivery and Air Induction. 2. Remove the retainers and the radiator sight shield. 3. Remove the 2 bolts and the lower cooling fan shroud. ^ To install, tighten to 3 Nm (27 inch lbs.). 4. Remove the 2 bolts and the upper cooling fan shroud. ^ To install, tighten to 3 Nm (27 inch lbs.). 5. Using the special tools, remove the cooling fan assembly. ^ To install, tighten to 55 Nm (41 ft. lbs.). 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Service and Repair > Removal and Installation > Page 3563 Fan Clutch: Service and Repair Disassembly and Assembly Cooling Fan and Fan Clutch Disassembly and Assembly 1. Remove the 4 cooling fan-to-cooling fan clutch bolts and separate the clutch from the cooling fan. ^ To assemble, tighten to 17 Nm (13 ft. lbs.). 2. To assemble, reverse the disassembly procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Service and Repair > Page 3564 Fan Clutch: Tools and Equipment Fan Clutch Holding Tool AST tool# 8005 Allows the technician to hold the water pump pulleuy in place while loosening the radiator fan. 2009 Suggested user price: $41.20 Assenmacher Specialty Tools 1 800 525 2943 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 3569 C107 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation > CHT Sensor Engine Temperature Sensor: Description and Operation CHT Sensor The CHT sensor: ^ is mounted into the wall of the cylinder head and is not connected to any coolant passages. ^ sends the PCM a signal indicating cylinder head temperature. ^ if the temperature exceeds approximately 121 °C (250°F), the PCM disables half of the fuel injectors at a time. The PCM will alternate which fuel injectors are disabled every 32 engine cycles. The cylinders that are not being fuel injected act as air pumps to aid in engine cooling. ^ if the temperature exceeds approximately 166°C (330°F), the PCM disables all of the fuel injectors until the engine temperature drops below approximately 1 54°C (31 0°F). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation > CHT Sensor > Page 3572 Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical Cylinder Head Temperature (CHT) Sensor The CHT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. The CHT sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM initiates a fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern such as low coolant or coolant loss could cause an overheating condition. As a result damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation > Page 3573 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR Removal and Installation 1. Remove the intake manifold. 2. Disconnect the cylinder head temperature (CHT) sensor jumper harness electrical connector. 3. Remove and discard the CHT sensor. - To install, tighten to 10 Nm (89 lb-in). - Coat the CHT sensor threads with high temperature nickel anti-seize lubricant prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair Fan Shroud: Service and Repair Cooling Fan - Blade, Clutch and Shroud Special Tool(s) Removal and Installation 1. Remove the air cleaner inlet pipe and resonator. For additional information, refer to Fuel Delivery and Air Induction. 2. Remove the retainers and the radiator sight shield. 3. Remove the 2 bolts and the lower cooling fan shroud. ^ To install, tighten to 3 Nm (27 inch lbs.). 4. Remove the 2 bolts and the upper cooling fan shroud. ^ To install, tighten to 3 Nm (27 inch lbs.). 5. Using the special tools, remove the cooling fan assembly. ^ To install, tighten to 55 Nm (41 ft. lbs.). 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 (V8-5.4L VIN 5 (2006)) 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 3585 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 (V8-5.4L VIN 5 (2006)) 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 3586 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 (V8-5.4L VIN 5 (2006)) 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 (V8-5.4L VIN 5 (2006)) 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 3592 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 (V8-5.4L VIN 5 (2006)) 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 3593 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3594 Heater Core: Testing and Inspection HEATER CORE 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. 1. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores were good and did not require replacement. If a heater core leak is suspected, the heater core must be tested by carrying out the plugged heater core component test before the heater core pressure test. Carry out a system inspection by checking the heater system thoroughly as follows: Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater water hose could follow the heater core tube to the heater core and appear as a leak in the heater core. 2. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of non-specification clamps can cause leakage at the heater water hose connection and damage the heater core. Check the integrity of the heater water hose clamps. 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 correct 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 is not working correctly. Heater Core - Pressure Test Use the Radiator/Heater Core Pressure Tester to perform the pressure test. 1. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. Drain the coolant from the cooling system. 2. Disconnect the heater 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 138 kPa (20 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of 3 minutes. 8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, remove the heater core from the vehicle and perform the bench test. Heater Core - Bench Test 1. Remove the heater core from the vehicle. 2. Drain all of the coolant from the heater core. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3595 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 138 kPa (20 psi) of air pressure to the heater core. Submerge the heater core in water. 5. If a leak is observed, install a new heater core. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core Heater Core: Service and Repair Heater Core HEATER CORE Removal and Installation NOTE: If a heater core leak is suspected, the heater core must be leak tested before it is removed from the vehicle. 1. Remove the heater core and evaporator core housing. 2. Remove the dash panel seal. 3. Remove the 3 temperature blend door actuator screws. 4. Remove the temperature blend door actuator. 5. Remove the 4 heater core cover screws. 6. Remove the heater core cover. 7. Remove the heater core. 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core > Page 3598 Heater Core: Service and Repair Auxiliary Heater Core AUXILIARY HEATER CORE Removal and Installation 1. Remove the auxiliary climate control housing. 2. Remove the screws and the evaporator/heater core access cover. 3. Remove the heater core. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 (V8-5.4L VIN 5 (2006)) 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 3607 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 (V8-5.4L VIN 5 (2006)) 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 3608 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 (V8-5.4L VIN 5 (2006)) 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 (V8-5.4L VIN 5 (2006)) 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 3614 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 (V8-5.4L VIN 5 (2006)) 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 3615 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Coupling Heater Hose: Service and Repair Heater Hose Coupling HEATER HOSE COUPLING Remover, Heater Hose Inlet Tube Special Tool(s) Disconnect 1. 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. Depressurize the engine cooling system. 2. Push the heater water hose toward the tube to fully expose the locking tabs. 3. NOTE: When compressing the white coupling retainer, the Heater Hose Disconnect Tool must be perpendicular to and on the highest point of the coupling. Push the special tool over the coupling retainer windows to compress the retainer locking tabs. 4. NOTE: A slight twisting motion while pulling on the heater water hose may be necessary to assist in the removal. Pull the heater water hose away from the heater core tube. 5. Plug the heater water hose. 6. Remove the white coupling retainer from the tube. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Coupling > Page 3618 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 MERPOL(R) meeting Ford specification ESE-M99B144-B or plain water. 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Coupling > Page 3619 Heater Hose: Service and Repair Auxiliary Heater Outlet and Inlet Line AUXILIARY HEATER OUTLET AND INLET LINE Removal CAUTION: To avoid refrigerant loss, clearly differentiate the auxiliary heater lines from the auxiliary refrigerant lines before beginning this procedure. NOTE: - The auxiliary heater inlet and outlet lines are not supplied together as an assembly. The auxiliary heater inlet line and outlet line are each installed from the factory as 1-piece assemblies. The replacement parts are supplied as separate kits containing multiple piece lines for ease of installation. - The following procedure can be used to remove and install 1 or both the auxiliary heater inlet and auxiliary heater outlet lines. If only one auxiliary heater line is to be removed and installed, cut or disconnect only the desired line at the specified points within the procedure. 1. Drain the engine coolant. 2. Remove the RH quarter trim panel. 3. Detach the auxiliary heater lines. 1 Disconnect the heater hose(s). 2 Remove the 2 line bracket bolts. 3 Remove the line bracket. 4. Remove the spare tire. 5. Raise the vehicle. 6. Remove the RH front wheel. 7. Remove the RH fender splash shield. 8. NOTE: If installing only one auxiliary heater line, disconnect only the desired line. Disconnect the heater hose(s). 9. Remove the muffler. 10. Remove the RH catalytic converter. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Coupling > Page 3620 11. Remove the 3 bolts and the heat shield. 12. Remove the bolts. 13. Remove the nut and the line bracket. 14. Remove the bolt and the heat shield. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Coupling > Page 3621 15. Remove the nuts and the remaining line brackets. 16. NOTE: If installing only one auxiliary heater line, cut only the desired line. Assemble and lay out the replacement line(s) in the same position as the existing line(s) and, using a suitable tool, cut the auxiliary heater line(s) in the same position as the fittings on the new line(s). 17. Remove the auxiliary heater line(s) in 3 separate pieces. Installation 1. Partially lower the vehicle. 2. Attach the rear portion of the auxiliary heater lines. 1 Connect the heater hoses. 2 Install the line bracket. 3 Install the bolts. 3. Install the front auxiliary heater line(s) and connect the heater hose(s). - Clean and lubricate the heater hoses with plain water only if needed. 4. Raise the vehicle. 5. NOTE: Loosely connect, but do not tighten, the fittings. Install the middle auxiliary heater line(s). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Coupling > Page 3622 6. Starting from the rear of the vehicle, install the first 3 line brackets. - Tighten to 5 Nm (44 lb-in). 7. Tighten the middle auxiliary heater line fittings. 8. Inspect the auxiliary heater lines for correct installation. Loosen, reposition and tighten as needed. 9. Install the heat shield and the bolts. - Tighten to 15 Nm (11 lb-ft). 10. Install the heat shield and the bolts. - Tighten to 15 Nm (11 lb-ft). 11. Install the RH catalytic converter. 12. Install the muffler. 13. Partially lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Coupling > Page 3623 14. Install the heat shield bolt. - Tighten to 15 Nm (11 lb-ft). 15. Install the line bracket. - Tighten to 5 Nm (44 lb-in). 16. Lower the vehicle. 17. Install the spare tire. 18. Install the RH quarter trim panel. 19. Fill the engine coolant level. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Testing and Inspection Radiator: Testing and Inspection Radiator Leak Test, Removed From Vehicle CAUTION: Never leak test an aluminum radiator in the same water that copper/brass radiators are tested in. Flux and caustic cleaners may be present in the cleaning tank and they will damage aluminum radiators. NOTE: Always install plugs in the oil cooler fittings before leak testing or cleaning any radiator. 1. Leak test the radiator in clean water with 138 kPa (20 psi) air pressure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Testing and Inspection > Page 3627 Radiator: Service and Repair Radiator Special Tool(s) Material Removal and Installation 1. Drain the engine cooling system. 2. Remove the pin-type retainers and the air deflector cover. 3. Remove the cooling fan and shroud. 4. Disconnect the upper radiator coolant hose from the radiator. 5. Disconnect the degas bottle return hose from the radiator. 6. Disconnect the lower radiator coolant hose from the radiator. 7. Push the special tool into the fitting to release the tube retaining clip and remove the transmission cooler lines from the radiator. 8. Remove the 2 bolts and the 2 radiator support brackets. ^ To install, tighten to 30 Nm (22 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Testing and Inspection > Page 3628 9. Remove the radiator and the 4 radiator insulators. 10. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection Radiator Cap: Testing and Inspection Cap - Pressure Relief 1. WARNING: Never remove the pressure relief cap while the engine is operating or when the cooling system is hot. Failure to follow these instructions can result in damage to the cooling system or engine or personal injury. To avoid having scalding hot coolant or steam blow out of the degas bottle when removing the pressure relief cap, wait until the engine has cooled, then wrap a thick cloth around the pressure relief cap and turn it slowly. Step back while the pressure is released from the cooling system. When you are sure all the pressure has been released, turn and remove the pressure relief cap (still with a cloth). Inspect the pressure relief cap and seals for damage or deterioration. Install a new pressure relief cap if necessary. 2. Fit the pressure relief cap to Radiator/Heater Core Pressure Tester Kit using the aftermarket adapter. 3. NOTE: If the plunger of the pressure tester is depressed too fast, an incorrect pressure reading will result. Slowly pump the pressure tester until the pressure gauge stops increasing and note the highest pressure reading. Release pressure and repeat test. Install a new pressure relief cap if the pressure is not between 99.3 - 121.4 kPa (14.4 - 17.6 psi). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Radiator Cooling Fan Speed Sensor > Component Information > Description and Operation Radiator Cooling Fan Speed Sensor: Description and Operation FAN SPEED SENSOR (FSS) Cooling Fan Clutch With Fan Speed Sensor (FSS) The FSS is a Hall-effect sensor that measures the cooling fan clutch speed by generating a waveform with a frequency proportional to the fan speed. If the cooling fan clutch is moving at a relatively low speed, the sensor produces a signal with a low frequency. As the cooling fan clutch speed increases, the sensor generates a signal with a higher frequency. The powertrain control module (PCM) uses the frequency signal generated by the FSS as a feedback for closed loop control of the cooling fan clutch. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 3640 C107 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation > CHT Sensor Engine Temperature Sensor: Description and Operation CHT Sensor The CHT sensor: ^ is mounted into the wall of the cylinder head and is not connected to any coolant passages. ^ sends the PCM a signal indicating cylinder head temperature. ^ if the temperature exceeds approximately 121 °C (250°F), the PCM disables half of the fuel injectors at a time. The PCM will alternate which fuel injectors are disabled every 32 engine cycles. The cylinders that are not being fuel injected act as air pumps to aid in engine cooling. ^ if the temperature exceeds approximately 166°C (330°F), the PCM disables all of the fuel injectors until the engine temperature drops below approximately 1 54°C (31 0°F). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation > CHT Sensor > Page 3643 Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical Cylinder Head Temperature (CHT) Sensor The CHT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. The CHT sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM initiates a fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern such as low coolant or coolant loss could cause an overheating condition. As a result damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation > Page 3644 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR Removal and Installation 1. Remove the intake manifold. 2. Disconnect the cylinder head temperature (CHT) sensor jumper harness electrical connector. 3. Remove and discard the CHT sensor. - To install, tighten to 10 Nm (89 lb-in). - Coat the CHT sensor threads with high temperature nickel anti-seize lubricant prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Thermostat Opening Temperatures Starts to open ...................................................................................................................................... .................................... 86.7 - 90.6°C (188 - 195°F) Fully open .......................................................... ................................................................................................................... 97.8 - 101.7°C (208 215°F) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 3648 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 3649 Thermostat: Testing and Inspection Thermostat A new thermostat should be installed only after these electrical and mechanical tests have been carried out. Thermostat - Electrical Test NOTE: The electrical thermostat test is most accurate if carried out indoors at less than 37.8°C (100°F) ambient air. This test may be carried out with or without the hood open and with the engine warm or cold. 1. Check the engine coolant level. Fill as needed. 2. With the ignition OFF, voltage values (0-5 V) may now be monitored while the cylinder head temperature (CHT) sensor retains its connection to the wiring harness. A diagnostic tool may be used to monitor the CHT on vehicles equipped with data link connector (DLC). The SBDS sequence to use for the screen is: Toolbox-Electronic Engine Control and DCL-Item. 3. Place the automatic transmission in PARK (P) or the manual transmission in NEUTRAL (N) and engage the parking brake. 4. Start the engine and allow the engine to idle throughout this test. Allow the engine to run for 2 minutes, then record the CHT voltage. Record the CHT voltage every 60 seconds. When the CHT voltage trend changes direction or only changes slightly (0.03 volt or less) from the previous reading, record this as the thermostat opening voltage. Use the voltage and corresponding coolant temperature chart. 5. If the coolant thermostat opening voltage is greater than 0.67 volt and less than 86°C (187°F), install a new coolant thermostat. 6. If the coolant thermostat opening voltage is less than 0.58 volt and greater than 86°C (187°F), the coolant thermostat is good and a new coolant thermostat should not be installed. GO to Symptom Chart for further instructions. See: Testing and Inspection/Symptom Related Diagnostic Procedures/Diagnosis By Symptom Thermostat - Mechanical Test 1. Remove the thermostat. 2. Check the thermostat for seating. Hold the thermostat up to a lighted background. Leakage of light around the thermostat valve at room temperature indicates that a new thermostat should be installed. Some thermostats have a small leakage notch at one location on the perimeter of the thermostat valve, which is considered normal. 3. Immerse the thermostat in a boiling antifreeze and water mixture. 4. For additional information, refer to Specifications for thermostat opening temperature. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 3650 Thermostat: Service and Repair Thermostat and Thermostat Housing Material Removal and Installation 1. Drain the engine cooling system. 2. If replacing the thermostat housing, disconnect the upper radiator hose from the thermostat. 3. Remove the 2 bolts, the thermostat housing and the thermostat. Discard the O-ring seal. ^ To install, tighten to 10 Nm (89 inch lbs.). 4. To install, reverse the removal procedure. ^ Inspect the sealing surfaces. Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging. ^ Install a new O-ring seal. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Diagrams > Page 3654 Thermostat Housing: Service and Repair Thermostat and Thermostat Housing Material Removal and Installation 1. Drain the engine cooling system. 2. If replacing the thermostat housing, disconnect the upper radiator hose from the thermostat. 3. Remove the 2 bolts, the thermostat housing and the thermostat. Discard the O-ring seal. ^ To install, tighten to 10 Nm (89 inch lbs.). 4. To install, reverse the removal procedure. ^ Inspect the sealing surfaces. Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging. ^ Install a new O-ring seal. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Water pump bolts ................................................................................................................................ ..................................................... 25 Nm (18 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 3658 Water Pump: Service and Repair Coolant Pump Material Removal and Installation 1. Drain the engine cooling system. 2. Remove the cooling fan. 3. Loosen the 4 coolant pump pulley bolts. ^ To install, tighten to 25 Nm (18 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 3659 4. Rotate the belt tensioner clockwise and disconnect the accessory drive belt from the coolant pump pulley. 5. Remove the 4 bolts and the coolant pump pulley. 6. Remove the 4 bolts and the coolant pump. ^ Discard the O-ring seal. ^ To install, tighten to 25 Nm (18 ft. lbs.). 7. To install, reverse the removal procedure. ^ Inspect the mating surfaces. Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging. ^ Install a new O-ring seal. Lubricate the O-ring seal with clean engine coolant prior to installation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation Catalytic Converter: Description and Operation CATALYST AND EXHAUST SYSTEMS Overview V-Engines In-Line Engines The catalytic converter and exhaust Systems work together to control the release of harmful engine exhaust emissions into the atmosphere. The engine exhaust gas consists mainly of nitrogen (N), carbon dioxide (CO2) and water vapor (H2O). However, it also contains carbon monoxide (CO), oxides of nitrogen (NOx), hydrogen (H), and various unburned hydrocarbons (HCs). The major air pollutants of CO, NOx, and HCs, and their emission into the atmosphere must be controlled. The exhaust system generally consists of an exhaust manifold, front exhaust pipe, front heated oxygen sensor (HO2S), rear exhaust pipe, catalyst HO2S, a muffler, and an exhaust tailpipe. The catalytic converter is typically installed between the front and rear exhaust pipes. On some vehicle applications, more than one catalyst is used between the front and rear exhaust pipes. Catalytic converter efficiency is monitored by the on-board diagnostic (OBD) system strategy in the PCM. For information on the OBD catalyst monitor, refer to the description for the Catalyst Efficiency Monitor. The number of HO2Ss used in the exhaust stream and the location of these sensors depend on the vehicle emission certification level (LEV, LEV-II, ULEV, PZEV). On most vehicles only 2 HO2Ss are used in an exhaust stream. The front sensors (HO2S11/HO2S21) before the catalyst are used for primary fuel control while the ones after the catalyst (HO2S12/HO2S22) are used to monitor catalyst efficiency. However, some partial zero emission vehicles (PZEV) use 3 HO2Ss for each engine bank. The stream 1 sensors (HO2S11/HO2S21) located before the catalyst are used for primary fuel control, the stream 2 sensors (HO2S12/HO2S22) are used to monitor the light-off catalyst, and the stream 3 sensors (HO2S13/HO2S23) located after the catalyst are used for long term fuel trim control to optimize catalyst efficiency (fore aft oxygen sensor control). Current PZEV vehicles use only a Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 3664 4-cylinder engine, so only the bank 1 HO2Ss are used. Catalytic Converter A catalyst is a material that remains unchanged when it initiates and increases the speed of a chemical reaction. A catalyst also enables a chemical reaction to occur at a lower temperature. The concentration of exhaust gas products released to the atmosphere must be controlled. The catalytic converter assists in this task. It contains a catalyst in the form of a specially treated ceramic honeycomb structure saturated with catalytically active precious metals. As the exhaust gases come in contact with the catalyst, they are changed into mostly harmless products. The catalyst initiates and speeds up heat producing chemical reactions of the exhaust gas components so they are used up as much as possible. Light Off Catalyst As the catalyst heats up, converter efficiency rises rapidly. The point at which conversion efficiency exceeds 50% is called catalyst light off. For most catalysts this point occurs at 246°C to 302°C (475°F to 575°F). A fast light catalyst is a 3-way catalyst (TWC) that is located as close to the exhaust manifold as possible. Because the light off catalyst is located close to the exhaust manifold it lights off faster and reduce emissions quicker than the catalyst located under the body. Once the catalyst lights off, the catalyst quickly reaches the maximum conversion efficiency for that catalyst. Three-Way Catalyst (TWC) Conversion Efficiency TWC Conversion Efficiency Chart A TWC requires a stoichiometric fuel ratio, 14.7 pounds of air to 1 pound of fuel (14.7:1), for high conversion efficiency. In order to achieve these high efficiencies, the air/fuel ratio must be tightly controlled with a narrow window of stoichiometry. Deviations outside of this window greatly decrease the conversion efficiency. For example a rich mixture decreases the HC and CO conversion efficiency while a lean mixture decreases the NOx conversion efficiency. Exhaust System Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 3665 Typical Bank 1 Catalyst 2 HO2S Configuration Typical Bank 1 Catalyst 3 HO2S Configuration The purpose of the exhaust system is to convey engine emissions from the exhaust manifold to the atmosphere. Engine exhaust emissions are directed from the engine exhaust manifold to the catalytic converter through the front exhaust pipe. A HO2S is mounted on the front exhaust pipe before the catalyst. The catalytic converter reduces the concentration of CO, unburned HCs, and NOx in the exhaust emissions to an acceptable level. The reduced exhaust emissions are directed from the catalytic converter past another HO2S mounted in the rear exhaust pipe and then on into the muffler. Finally, the exhaust emissions are directed to the atmosphere through an exhaust tailpipe. On some PZEV, there is a total of 3 HO2S in the exhaust stream. One near the exhaust manifold (stream 1), one in the middle of the light-off catalyst (stream 2), and the third (stream 3) is mounted after the light-off catalyst. Underbody Catalyst The underbody catalyst is located after the light off catalyst. The underbody catalyst may be in-line with the light off catalyst, or the underbody catalyst may be common to 2 light off catalysts, forming a Y pipe configuration. For an exact configuration of the catalyst and exhaust system for a specific vehicle, refer to Catalytic Converter, Exhaust System. Three-Way Catalytic (TWC) Converter The TWC converter contains either platinum (Pt) and rhodium (Rh) or palladium (Pd) and rhodium (Rh). The TWC converter catalyzes the oxidation Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 3666 reactions of unburned HCs and CO and the reduction reaction of NOx. The 3-way conversion can be best accomplished by always operating the engine air fuel/ratio at or close to stoichiometry. Exhaust Manifold Runners The exhaust manifold runners collect exhaust gases from engine cylinders. The number of exhaust manifolds and exhaust manifold runners depends on the engine configuration and number of cylinders. Exhaust Pipes Exhaust pipes are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The pipes serve as guides for the flow of exhaust gases from the engine exhaust manifold through the catalytic converter and the muffler. Heated Oxygen Sensors (HO2S) The HO2S provide the powertrain control module (PCM) with voltage and frequency information related to the oxygen content of the exhaust gas. Muffler Mufflers are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The muffler reduces the level of noise produced by the engine, and also reduces the noise produced by exhaust gases as they travel from the catalytic converter to the atmosphere. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust manifold nuts ......................................................................................................................... ................................................. 25 Nm (18 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > General Procedures Exhaust Manifold: Service and Repair General Procedures Exhaust Manifold-Inspection Special Tools And Equipment Special Tool(s) 1. Place a straight edge across the exhaust manifold flanges and check for warping with a feeler gauge. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > General Procedures > Page 3672 Exhaust Manifold: Service and Repair Exhaust Manifold - LH Exhaust Manifold - LH Special Tool(s) Material Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > General Procedures > Page 3673 All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the air cleaner housing. For additional information, refer to Fuel Delivery and Air Induction. 3. Remove the generator. For additional information, refer to Alternator. 4. Remove the LH inner fenderwell. 5. Remove the upper radiator shroud. For additional information, refer to Cooling System. 6. CAUTION: Only use hand tools when removing the LH engine mount through bolt or damage to the cage nut can occur. NOTE: If the LH engine mount through bolt nut is missing or damaged install a new nut using service part number W709375. If the LH engine mount through bolt nut cage is damaged or missing, remove the cage and install a new nut using service part number W520516-S301. Remove the LH engine support insulator bolt. ^ To install, tighten to 175 Nm (129 ft. lbs.). 7. CAUTION: Only use hand tools when loosening the RH engine mount nut or damage to the engine mount can occur. Loosen the RH engine mount nut. ^ To install, tighten to 175 Nm (129 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > General Procedures > Page 3674 8. Remove the 4 exhaust manifold-to-catalytic converter nuts. ^ To install, tighten to 40 Nm (30 ft. lbs.). 9. CAUTION: Only use hand tools when removing the transmission mount-to-crossmember nuts or damage to the transmission mount can occur. Loosen the 2 transmission mount-to-crossmember nuts. ^ To install, tighten to 103 Nm (76 ft. lbs.). 10. Remove the 2 bolts and the exhaust manifold heat shield. ^ To install, tighten to 10 Nm (89 inch lbs.). 4WD vehicles 11. Remove the front driveshaft. All vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > General Procedures > Page 3675 12. Install the special tools and raise the engine. 13. Remove the 8 nuts and the exhaust manifold. ^ To install, tighten to 25 Nm (18 ft. lbs.) in the sequence shown. 14. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces. NOTE: Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging. Remove and discard the exhaust manifold gaskets. Clean the sealing surfaces with metal surface prep. 15. Inspect the exhaust manifold. 16. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > General Procedures > Page 3676 Exhaust Manifold: Service and Repair Exhaust Manifold - RH Exhaust Manifold - RH Special Tool(s) Material Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > General Procedures > Page 3677 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the air cleaner housing. For additional information, refer to Fuel Delivery and Air Induction. 3. Remove the generator. For additional information, refer to Alternator. 4. Remove the starter. For additional information, refer to Starter. 5. Remove the RH inner fenderwell. 6. Remove the upper radiator shroud. For additional information, refer to Cooling System. 7. CAUTION: Only use hand tools when loosening the LH engine mount through bolt or damage to the cage nut can occur. NOTE: If the LH engine mount through bolt nut is missing or damaged install a new nut using service part number W709375. If the LH engine mount through bolt nut cage is damaged or missing, remove the cage and install a new nut using service part number W520516-S301. Loosen the LH engine support insulator bolt. ^ To install, tighten to 175 Nm (129 ft. lbs.). 8. CAUTION: Only use hand tools when removing the RH engine mount nut or damage to the engine mount can occur. Remove the RH engine mount nut. ^ To install, tighten to 175 Nm (129 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > General Procedures > Page 3678 9. Remove the 4 exhaust manifold-to-catalytic converter nuts. ^ To install, tighten to 40 Nm (30 ft. lbs.). 10. CAUTION: Only use hand tools when removing the transmission mount-to-crossmember nuts or damage to the transmission mount can occur. Loosen the 2 transmission mount-to-crossmember nuts. ^ To install, tighten to 103 Nm (76 ft. lbs.). 11. Remove the 4 bolts and position the sway bar down. ^ To install, tighten to 30 Nm (22 ft. lbs.). 12. Install the special tools and raise the engine. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > General Procedures > Page 3679 13. Remove the 8 nuts and the exhaust manifold. ^ To install, tighten to 25 Nm (18 ft. lbs.) in the sequence shown. 14. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces. NOTE: Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging. Remove and discard the exhaust manifold gaskets. Clean the sealing surfaces with metal surface prep. 15. Inspect the exhaust manifold. 16. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair Exhaust Pipe: Service and Repair Exhaust Y-Pipe - Dual Catalytic Converter Material Removal CAUTION: Do not use oil- or grease-based lubricants on isolators as they deteriorate the rubber. NOTE: The exhaust Y-pipe-dual catalytic converter is a 2-piece assembly. The RH and LH converters can be serviced separately as needed. Both RH and LH catalytic converters 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Disconnect the heated oxygen and catalyst monitor sensors. 3. NOTE: LH catalytic converter-to-exhaust manifold nuts shown, RH similar. Remove and discard the catalytic converter-to-exhaust manifold nuts. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Page 3683 4. Loosen the RH catalytic converter to LH catalytic converter clamp. LH converter only 5. NOTE: Use caution removing the catalytic converter. Make sure not to damage the manifold outlet flare, the converter inlet flare or the studs. Separate and remove the LH converter. RH converter only 6. Remove and discard the bolts and flag nuts at the RH converter-to-muffler flange. 7. Using a suitable jack stand, support the muffler. 8. Detach the isolators from the muffler assembly. 9. Lower the muffler assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Page 3684 10. NOTE: Use caution removing the catalytic converter. Make sure not to damage the manifold outlet flare, the converter inlet flare or the studs. Remove the transmission mounting bracket isolator cap bolt, transmission mounting bracket isolator cap and the RH converter. Both RH and LH catalytic converters 11. If necessary, remove the heated oxygen and the catalyst monitor sensors. Installation Both RH and LH catalytic converters CAUTION: Do not tighten the fasteners until all components are assembled and aligned, making sure to tighten all fasteners beginning at the front of the vehicle. NOTE: Clean the mating surfaces of the manifold outlet flare and the catalytic converter inlet flare. Also clean the mating surfaces of the muffler inlet pipe and catalytic converter. Make sure not to damage the manifold outlet flare, the converter inlet flare or the studs. NOTE: Always install new fasteners and gaskets. 1. NOTE: Make sure to apply anti-seize lubricant to the threads of the sensors before installation. If removed, install the heated oxygen and the catalyst monitor sensors. ^ Tighten to 40 Nm (30 ft. lbs.). RH catalytic converter 2. If not already installed, position the RH catalytic converter-to-LH catalytic converter clamp. 3. NOTE: Use caution installing the catalytic converter. Make sure not to damage the manifold outlet flare, the converter inlet flare or the studs. Position the RH catalytic converter and loosely install the nuts to the exhaust manifold. 4. Install the transmission mounting bracket isolator cap and loosely install the bolt. 5. Install the isolators to the muffler assembly. 6. Loosely install new RH catalytic converter-to-muffler bolts and flag nuts. LH catalytic converter 7. If not already installed, position the RH catalytic converter to LH catalytic converter clamp. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Page 3685 8. NOTE: Use caution installing the catalytic converter. Make sure not to damage the manifold outlet flare, the converter inlet flare or the studs. Position the LH catalytic converter and loosely install the nuts to the exhaust manifold. RH and LH catalytic converters 9. Align the exhaust system. 10. To seat the RH catalytic converter to the RH exhaust manifold, tighten the new catalytic converter nuts in this sequence. ^ Tighten the upper nut to 40 Nm (30 ft. lbs.). ^ Tighten the lower nut to 40 Nm (30 ft. lbs.). 11. Tighten the transmission mounting bracket isolator cap bolt. ^ Tighten to 35 Nm (26 ft. lbs.). 12. Tighten the RH catalytic converter-to-LH catalytic converter clamp. ^ Tighten to 48 Nm (35 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Page 3686 13. To seat the LH catalytic converter to the LH exhaust manifold, tighten the new catalytic converter nuts in this sequence. ^ Snug the inner nut. ^ Tighten the outer nut to 40 Nm (30 ft. lbs.). ^ Tighten the inner nut to 40 Nm (30 ft. lbs.). 14. Tighten the RH catalytic converter-to-muffler bolts and flag nuts. ^ Tighten to 48 Nm (35 ft. lbs.). 15. Connect the heated oxygen and catalyst monitor sensors. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair Heat Shield: Service and Repair Exhaust Heat Shields Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Inspect the exhaust system for loose or missing heat shields or foreign material trapped between the heat shields and the exhaust system components. 3. If any heat shields are loose, install worm gear clamps. ^ Use either of these clamps: F0TZ-5A231-A or W705949-S300. ^ To install, tighten to 7 Nm (62 inch lbs.). ^ Trim off the excess ear of the worm clamp. 4. If the heat shields are missing, install new heat shields or exhaust system components as necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair Muffler: Service and Repair Muffler and Tailpipe Removal and Installation CAUTION: Do not use oil- or grease-based lubricants on isolators as they deteriorate the rubber. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Loosen the clamp, separate the isolator from the hanger and remove: ^ An extension pipe for Expedition models. ^ A resonator for Navigator models. ^ To install, tighten to 48 Nm (35 ft. lbs.). 3. Remove the 4 nuts and 2 stabilizer bar brackets. ^ Allow the bar to hang from the links. ^ To install, tighten to 55 Nm (41 ft. lbs.). 5. Detach the isolators from the muffler. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 3693 6. Remove and discard the bolts and flag nuts. ^ To install, tighten to 48 Nm (35 ft. lbs.). 7. CAUTION: Make sure not to make contact with the axle boots while routing the muffler outlet over the rear axle or damage to the boots may result. Remove the muffler and tailpipe assembly. 8. NOTE: Clean the mating surfaces of the inlet pipe and catalytic converter. NOTE: Always install new fasteners. NOTE: Check the exhaust hanger isolators for wear or damage, install new isolators, if necessary. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations Body Control Module: Locations VEHICLE SECURITY MODULE (VSM) View 151-17 (RH A-Pillar) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 3700 Body Control Module: Diagrams VEHICLE SECURITY MODULE (VSM) C2113a C2113b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 3701 C2113c Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) Body Control Module: Service and Repair Driver Seat Module (DSM) DRIVER SEAT MODULE (DSM) Removal and Installation CAUTION: - Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. - Prior to the removal of the module, it is necessary to upload module configuration information to the appropriate diagnostic equipment. This information needs to be downloaded into the new module once installed. 1. NOTE: The module is accessed with the seat fully in the UP position. Position the driver seat module forward to remove it from the bracket. 2. Disconnect the battery. 3. Disconnect the electrical connectors and remove the DSM. 4. CAUTION: Once the module is installed it is necessary to download the module configuration information from the diagnostic tool into the new module. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 3704 Body Control Module: Service and Repair Vehicle Security Module VEHICLE SECURITY MODULE Removal CAUTION: The steps included in the vehicle security module removal and installation procedure are critical to restoring the vehicle security and tire pressure monitoring systems to normal operation. A new vehicle security module is delivered in manufacturing mode with 6 pre-set diagnostic trouble codes (DTCs) related to the tire pressure monitoring system (TPMS). The presence of these DTCs requires the installation procedures be followed in order to clear the DTCs and enable normal vehicle security module operations. 1. NOTE: Prior to the removal of the vehicle security module, it is necessary to upload the module configuration information to the diagnostic tool. This information must be downloaded to the new vehicle security module after installation. Disconnect the battery. 2. Remove the pin-type retainer and the RH A-pillar lower trim panel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 3705 3. Remove the glove compartment. 4. Disconnect the 3 electrical connectors. 5. Remove the 2 screws and the vehicle security module. Installation 1. Position the vehicle security module and install the 2 screws. - Tighten the screws to 6 Nm (53 lb-in). 2. Connect the 3 electrical connectors. 3. Position the RH A-pillar lower trim panel and install the pin-type retainer. 4. Install the glove compartment 5. Connect the battery. 6. NOTE: When successful, this step provides the calibration necessary for vehicle security module operation and clears DTC B2477. The clearing of the DTC indicates the calibration data has been successfully downloaded to the vehicle security module. Download the vehicle security module configuration information from the diagnostic tool to the vehicle security module. 7. NOTE: When successful, this step clears DTCs B2868, B2869, B2870 and B2871. The clearing of these DTCs indicates the vehicle security module has recognized the tire pressure sensors during the training procedure. Train the tire pressure sensors. 8. Clear the DTCs. 9. NOTE: - DTC C2780 will not clear if any other DTCs are present in the vehicle security module. - This step is required to clear DTC C2780, allow the vehicle security module to exit the manufacturing mode, and to be sure there are no other concerns with the newly programmed vehicle security module. Carry out the vehicle security module on-demand self-test. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation Electronic Throttle Control Module: Description and Operation TORQUE BASED ELECTRONIC THROTTLE CONTROL (ETC) Overview The torque based ETC is a hardware and software strategy that delivers an engine output torque (via throttle angle) based on driver demand (pedal position). It uses an electronic throttle body, the powertrain control module (PCM), and an accelerator pedal assembly to control the throttle opening and engine torque. The ETC system replaces the standard cable operated accelerator pedal, idle air control (IAC) valve, 3-wire throttle position sensor (TPS), and mechanical throttle body. Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque during shifts, and by calculating this desired torque, the system prevents engine lugging (low RPM and low manifold vacuum) while still delivering the performance and torque requested by the driver. It also enables many fuel economy/emission improvement technologies such as variable camshaft timing (VCT) (deliver same torque during transitions). Torque based ETC also results in less intrusive vehicle and engine speed limiting, along with smoother traction control. Other benefits of ETC are: eliminate cruise control actuators - eliminate idle air control (IAC) valve - better airflow range - packaging (no cable) - more responsive powertrain at altitude and improved shift quality It should be noted that the ETC system illuminates a powertrain malfunction indicator (wrench) on the instrument cluster when a concern is present. Concerns are accompanied by diagnostic trouble codes (DTCs) and may also illuminate the malfunction indicator lamp (MIL). Electronic Throttle Body (ETB) The ETB has the following characteristics: 1. The throttle actuator control (TAC) motor is a DC motor controlled by the PCM (requires 2-wires). The gear ratio from the motor to the throttle plate shaft is 17:1. 2. There are 2 designs: parallel and in-series. The parallel design has the motor under the bore parallel to the plate shaft. The motor housing is integrated into the main housing. The in-series design has a separate motor housing. 3. Two springs are used: one is used to close the throttle (main spring) and the other is in a plunger assembly that results in a default angle when no power is applied. This is for limp home reasons (the force of the plunger spring is 2 times stronger than the main spring). The default angle is usually set to result in a top vehicle speed of 48 km/h (30 mph) Typically this throttle angle is 7 to 8 degrees from the hard-stop angle. 4. The closed throttle plate hard stop is used to prevent the throttle from binding in the bore (~0.75 degree). This hard stop setting is not adjustable and is set to result in less airflow than the minimum engine airflow required at idle. 5. Unlike cable operated throttle bodies, the intent for the ETB is not to have a hole in the throttle plate or to use plate sealant. The hole is not required in the ETB because the required idle airflow is provided by the plate angle in the throttle body assembly. This plate angle controls idle, idle quality, and eliminates the need for an IAC valve. 6. The throttle position (TP) sensor has 2 signal circuits in the sensor for redundancy. The redundant throttle position signals are required for increased monitoring reasons. The first TP signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). During normal operation the negative slope TP signal (TP1) is used by the control strategy as the indication of throttle position. The TP sensor assembly requires 4 circuits. 5-volt reference voltage - Signal return (ground) - TP1 voltage with negative voltage slope (5-0 volts) - TP2 voltage with positive voltage slope (0-5 volts) Accelerator Pedal Position (APP) Sensors Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 3709 Electronic Throttle Body (ETB) And Accelerator Pedal Assembly The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1. There are 3 pedal position signals required for system monitoring. APP1 has a negative slope (increasing angle, decreasing voltage) and APP2 and APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. 2. There are 2 VREF circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. 2 reference voltage circuits (5 volts) - 2 signal return (ground) circuits - APP1 voltage with negative voltage slope (5-0 volts) - APP2 voltage with positive voltage slope (0-5 volts) - APP3 voltage with positive voltage slope (0-5 volts) 3. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. 4. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. A value is substituted for an incorrect signal if 2 of the 3 signals are incorrect. Electronic Throttle Control (ETC) System Strategy Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 3710 ETC System The torque based ETC strategy was developed to improve fuel economy and to accommodate variable camshaft timing (VCT). This is possible by not coupling the throttle angle to the driver pedal position. Uncoupling the throttle angle (produce engine torque) from the pedal position (driver demand) allows the powertrain control strategy to optimize fuel control and transmission shift schedules while delivering the requested wheel torque. The ETC monitor system is distributed across 2 processors within the PCM: the main powertrain control processor unit (CPU) and a monitoring processor called an enhanced-quizzer (E-Quizzer) processor. The primary monitoring function is carried out by the independent plausibility check (IPC) software, which resides on the main processor. It is responsible for determining the driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the generated torque exceeds driver demand by a specified amount, the IPC takes appropriate corrective action. ETC System Failure Mode And Effects Management (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 3711 ETC System Failure Mode And Effects Management (Part 2) Since the IPC and the main controller share the same processor, they are subject to a number of potential common failure modes. Therefore, the E-Quizzer processor was added to redundantly monitor selected PCM inputs and to act as an intelligent watchdog and monitor the performance of the IPC and the main processor. If it determines that the IPC function is impaired in any way, it takes appropriate failure mode and effects management (FMEM) actions. Electronic Throttle Monitor Operation: Electronic Throttle Monitor Operation (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 3712 Electronic Throttle Monitor Operation (Part 2) Accelerator and Throttle Position (TP) Sensor Inputs Accelerator Pedal Position (APP) Sensor Check: Accelerator Pedal Position (APP) Sensor Check Throttle Position (TP) Sensor Check: Throttle Position (TP) Sensor Check Throttle Plate Position Controller (TPPC) Outputs Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 3713 Throttle Plate Controller Check Operation The purpose of the TPPC is to maintain the throttle position at the desired throttle angle. It is a separate chip embedded in the PCM. The desired angle is communicated from the main CPU via a 312.5 Hz duty cycle (DC) signal. The TPPC interprets the duty cycle signal as follows: Less than 5% - Out of range, limp home default position. - Greater than or equal to 5% but less than 6% - Commanded default position, closed. - Greater than or equal to 6% but less than 7% - Commanded default position. Used for key-on, engine off. - Greater than or equal to 7% but less than 10% - Closed against hard-stop. Used to learn zero throttle angle position (hard-stop) after key-up. - Greater than or equal to 10% but less than or equal to 92% - Normal operation, between 0 degrees (hard-stop) and 82 degrees, 10% duty cycle equals 0 degrees throttle angle, 92% duty cycle equals 82 degrees throttle angle. - Greater than 92% but less than or equal to 96% - Wide Open Throttle, 82 to 86 degrees throttle angle. - Greater than 96% but less than or equal to 100% - Out of Range, limp home default position. The desired angle is relative to the hard-stop angle. The hard-stop angle is learned during each key-up process before the main CPU requests the throttle plate be closed against the hard-stop. The output of the TPPC is a voltage request to the H-driver (also in PCM). The H driver is capable of positive or negative voltage to the electronic throttle body motor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations View 151-1 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3719 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3720 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3721 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3722 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3723 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3724 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3725 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3726 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3727 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3728 Engine Control Module: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3729 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3730 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3731 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3732 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3733 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3734 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3735 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3736 Engine Control Module: Connector Views C175b (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3737 C175b (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3738 C175e (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3739 C175e (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3740 C175t (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3741 C175t (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 > Flash Electrically Erasable Programmable Read Only Memory (EEPROM) Engine Control Module: Service and Repair Flash Electrically Erasable Programmable Read Only Memory (EEPROM) FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) Description The flash electrically erasable programmable read only memory (EEPROM) is contained in an integrated circuit (IC) internal to the powertrain control module (PCM). The EEPROM contains the vehicle strategy including calibration information specific to the vehicle, and is capable of being programmed or flashed repeatedly. As part of the calibration there is an area referred to as the vehicle identification (VID) block. The VID block is programmed when installing a new PCM as described under Programming the VID Block for a Replacement PCM. Failure to carry out this procedure may generate fault code P1635 or P1639. The VID block in an existing PCM can also be tailored to accommodate various hardware or parameter changes made to the vehicle since production. Failure to carry out this procedure properly may generate fault code P1635, Tire/Axle Ratio out of Acceptable Range. An incorrect tire/axle ratio is one of the main causes for fault code P1639. This is described under Making Changes to the VID Block and also under Making Changes to the PCM Calibration. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the vehicle identification number (VIN), octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control, and 4-wheel drive electronic shift-on-the-fly (ESOF) versus manual shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported by the VID block is displayed on the diagnostic tool. When changing items in the VID block, the strategy places range limits on certain items such as tire and axle ratio. The number of times the VID block may be reconfigured is limited. When this limit is reached, the diagnostic tool displays a message indicating the need to flash the PCM again to reset the VID block. Programming can be carried out by a local Ford dealer or any non-Ford facility. Refer to the diagnostic tool manufacturer's instruction manual for details. Programming the VID Block for a Replacement PCM A new PCM contains the latest strategy and calibration level for a particular vehicle. However, the VID block is blank and will need programming. There are 2 procedures available. The first is an automatic data transfer from the old PCM to the new PCM, and the second is manual data entry into the new PCM. Automatic data transfer is carried out if the old PCM is capable of communicating. This is done by the use of a diagnostic tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can then be downloaded to the new PCM after it has been installed. Manual data entry must be carried out if the old module is damaged or incapable of communicating. Remove and install a new PCM. Using a compatible diagnostic tool, select and carry out the module/parameter programming, referring to the diagnostic tool manufacturer's instruction manual. Make certain that all parameters are included. Failure to properly program tire size in revolutions per mile, (rev/mile equals 63,360 divided by the tire circumference in inches), axle ratio, 4x4/4x2, and/or MSOF/ESOF may result in codes P1635 and P1639. You may be instructed to contact the As-Built Data Center for the information needed to manually update the VID block with the diagnostic tool. Contact the center only if the old PCM cannot be used or the data is corrupt. For Ford and L-M technicians, contact your National Hotline or the Professional Technician Society (PTS) website for As-Built data listed under the Service Publications Index. Non-Ford technicians use the Motorcraft(R) website at www.motorcraft.com. From the Motorcraft(R) homepage, use the search function to find the Module Programming or As-Built Data. For Ford and L-M technicians, check the Programmable Module Installation link on the PTS website for quick Programmable Module data information by vehicle when using the worldwide diagnostic system (WDS) or New Generation STAR (NGS). Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate the vehicle hardware. Refer to PCM/Module Reprogramming on the diagnostic tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM needs to be completely reprogrammed. This is due to changes made to the strategy or calibration after production, or the need to reset the VID block because it has reached its limit. Refer to PCM/Module Reprogramming on the diagnostic tool. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 > Flash Electrically Erasable Programmable Read Only Memory (EEPROM) > Page 3744 Engine Control Module: Service and Repair Removal and Installation POWERTRAIN CONTROL MODULE (PCM) Special Tool(s) Special Tool(s) Removal and Installation 1. NOTE: Refer to Computers and Control Systems for correct worldwide diagnostic system (WDS) hook-up procedure. If servicing the powertrain control module (PCM), connect the diagnostic tool to the vehicle. Allow the diagnostic tool to identify the vehicle and obtain configuration data. All programmable module information will automatically be retrieved by the WDS. 2. Disconnect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 > Flash Electrically Erasable Programmable Read Only Memory (EEPROM) > Page 3745 3. Disconnect the PCM electrical connectors. 4. Remove the 4 bolts and the PCM. - To install, tighten to 7 Nm (62 lb-in). 5. If servicing the PCM bracket, remove the 3 bolts and the PCM bracket. - To install, tighten to 10 Nm (89 lb-in). 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3749 C2160 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3750 Main Relay (Computer/Fuel System): Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3751 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations View 151-36 (Chassis, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 3756 C4033 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 3757 Fuel Pump Control Unit: Service and Repair Fuel Pump Driver Module (FPDM) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. NOTE: The fuel pump driver module (FPDM) is located on the top of the LH frame rail near the fuel tank filler pipe. Disconnect the FPDM electrical connector. 4. Remove the bolts and the FPDM. - To install, tighten to 10 Nm (89 lb-in). 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 (V8-5.4L VIN 5 (2006)) 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 3761 View 151-1 (Engine Compartment) The fuel pump relay is located in the Central Junction Box (CJB) and is Not Serviceable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3765 C2160 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3766 Main Relay (Computer/Fuel System): Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 3767 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3773 C2040 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3774 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The APP sensor is an input to the powertrain control module (PCM) and is used to determine the torque demand. There are 3 pedal position signals in the sensor. Signal 1, APPS1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, APPS2 and APPS3, both have a positive slope (increasing angle, increasing voltage). During normal operation APPS1 is used as the indication of pedal position by the strategy. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. There are 2 reference voltage circuits and 2 signal return circuits for the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3778 C1454 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3779 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW (MAF) SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT Sensor Wire Where Applicable) Terminals Typical Mass Air Flow (MAF) Sensor Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3780 Typical Drop-in Mass Air Flow (MAF) Sensor The MAF sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above the ambient temperature as measured by a constant cold wire. If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the mass air flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. Most MAF sensors have integrated bypass technology (IBT) with an integrated intake air temperature (IAT) sensor. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3781 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the mass air flow (MAF) sensor electrical connector. 3. Remove the 2 bolts and the MAF sensor. - To install, tighten to 7 Nm (62 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1 C1366 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1 > Page 3787 C1367 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3788 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR Typical Synchronizer Hall-Effect CMP Sensor Typical Variable Reluctance CMP Sensor The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston No. 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to select the correct ignition coil to fire. Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor and the 2-pin connector variable reluctance type sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3789 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the camshaft position (CMP) sensor electrical connector. 3. Remove the bolt and the CMP sensor. Discard the O-ring seal. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Description and Operation Clutch Switch: Description and Operation CLUTCH PEDAL POSITION (CPP) SWITCH Typical Clutch Pedal Position (CPP) Switch The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine load. The PCM uses the load information for mass air flow and fuel calculations. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3796 C101 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3797 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Typical Crankshaft Position (CKP) Sensor The CKP sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L 10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3798 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the accessory drive belt. 4. Disconnect the A/C compressor electrical connector. 5. Remove the 3 bolts and position the A/C compressor aside. - To install, tighten to 25 Nm (18 lb-ft). 6. Disconnect the crankshaft position (CKP) sensor electrical connector. 7. Remove the bolt and the CKP sensor. Discard the O-ring seal. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the new O-ring seal with clean engine oil prior to installation. 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 3802 C107 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > CHT Sensor Engine Temperature Sensor: Description and Operation CHT Sensor The CHT sensor: ^ is mounted into the wall of the cylinder head and is not connected to any coolant passages. ^ sends the PCM a signal indicating cylinder head temperature. ^ if the temperature exceeds approximately 121 °C (250°F), the PCM disables half of the fuel injectors at a time. The PCM will alternate which fuel injectors are disabled every 32 engine cycles. The cylinders that are not being fuel injected act as air pumps to aid in engine cooling. ^ if the temperature exceeds approximately 166°C (330°F), the PCM disables all of the fuel injectors until the engine temperature drops below approximately 1 54°C (31 0°F). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > CHT Sensor > Page 3805 Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical Cylinder Head Temperature (CHT) Sensor The CHT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. The CHT sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM initiates a fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern such as low coolant or coolant loss could cause an overheating condition. As a result damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > Page 3806 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR Removal and Installation 1. Remove the intake manifold. 2. Disconnect the cylinder head temperature (CHT) sensor jumper harness electrical connector. 3. Remove and discard the CHT sensor. - To install, tighten to 10 Nm (89 lb-in). - Coat the CHT sensor threads with high temperature nickel anti-seize lubricant prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation FUEL LEVEL INPUT (FLI) NOTE: The Ford GT uses a piezoelectric sonar type fuel level sensor. The sensor is located in the tank and the sensor signal is provided as a communications network message by the instrument cluster to the PCM. The FLI is either a hard wire signal input to the PCM from the fuel pump (FP) module or a communications network message. Most vehicle applications use a potentiometer type FLI sensor connected to a float in the FP module to determine fuel level. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 3810 Fuel Level Sensor: Service and Repair FUEL PUMP MODULE Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 3811 Part 2 Exploded View Special Tool(s) Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 3812 Removal and Installation WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. 1. Remove the fuel tank. 2. Disconnect the fuel and vapor tubes from the fuel pump module. 3. Using the special tool, remove the fuel pump lock ring. 4. CAUTION: Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 3813 - Note the location of the fuel pump alignment tabs. - Carefully remove the fuel pump assembly to avoid damaging the fuel level sensor. Remove the fuel pump module assembly. Remove and discard the O-ring seal. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 FUEL TANK PRESSURE (FTP) SENSOR Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The FTP sensor or in-line FTP sensor is used to measure the fuel tank pressure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 > Page 3817 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR Removal and Installation 1. Remove the fuel tank. 2. Disconnect the fuel vapor tube quick connect couplings from the fuel vapor/grade vent valves. 3. Disconnect the fuel vapor tube quick connect couplings from the fuel pump module. 4. Remove the fuel pressure sensor tube assembly. 5. To install, reverse the removal procedure. - Leak test the system. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Evaporative Emission System Leak Test - Carry out the evaporative emission repair verification drive cycle. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Evaporative Emission Repair Verification Drive Cycle Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3821 C1454 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3822 Intake Air Temperature Sensor: Description and Operation INTAKE AIR TEMPERATURE (IAT) SENSOR Typical Stand-Alone/Non-Integrated Intake Air Temperature (IAT) Sensors Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into A Drop-in Or Flange-type MAF Sensor The IAT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3823 fuel, spark, and air flow. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Currently there are 2 design types of IAT sensors used, a stand-alone/non-integrated type and a integrated type. Both types function the same, however the integrated type is incorporated into the mass air flow (MAF) sensor instead of being a stand alone sensor. Supercharged vehicles use 2 IAT sensors. Both sensors are thermistor type devices and operate as described. However, one is located before the supercharger at the air cleaner for standard OBD/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 C109 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 3829 C108 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 3830 Knock Sensor: Description and Operation KNOCK SENSOR (KS) Two Types Of Knock Sensor (KS) The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 3831 Knock Sensor: Service and Repair KNOCK SENSOR (KS) Removal and Installation 1. Remove the intake manifold. 2. Disconnect the knock sensor (KS) electrical connectors. 3. Remove the 2 bolts and the 2 knock sensors. - To install, tighten to 20 Nm (15 lb-ft). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair ENGINE OIL PRESSURE (EOP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Disconnect the engine oil pressure (EOP) sensor electrical connector. 4. Remove the EOP sensor. - To install, tighten to 21 Nm (15 lb-ft). 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations > Page 3838 C104 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations > Page 3839 Oil Temperature Sensor For ECM: Description and Operation ENGINE OIL TEMPERATURE (EOT) SENSOR Typical Engine Oil Temperature (EOT) Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system. The PCM can use the EOT sensor input to determine the following: - On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM begins reducing power by disabling engine cylinders. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations > Page 3840 Oil Temperature Sensor For ECM: Service and Repair OIL TEMPERATURE SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Drain the engine oil. 4. Disconnect the engine oil temperature (EOT) sensor electrical connector. 5. Remove the EOT sensor. Discard the O-ring seal. - To install, tighten to 21 Nm (15 lb-ft). - Install a new O-ring seal. Lubricate the new O-ring seal with clean engine oil prior to installation. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3845 Oxygen Sensor: Harness Locations View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3846 View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3847 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3848 View 151-8 (Transmission - 6HP26 Automatic Transmission Without Four-Wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3849 View 151-9 (Transmission - 6HP26 Automatic Transmission With Four-Wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3850 View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3851 View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3852 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3853 View 151-8 (Transmission - 6HP26 Automatic Transmission Without Four-Wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3854 View 151-9 (Transmission - 6HP26 Automatic Transmission With Four-Wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 C141 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 3857 C142 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 3858 C171 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 3859 C172 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3860 Oxygen Sensor: Description and Operation HEATED OXYGEN SENSOR (HO2S) Heated Oxygen Sensor (HO2S) The HO2S detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to a temperature of 800°C (1,472°F). At approximately 300°C (572°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater. The PCM turns the heater on by providing the ground when the correct conditions occur. The heater allows the engine to enter closed loop operation sooner. The use of this heater requires the HO2S heater control to be duty cycled, to prevent damage to the heater. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) HEATED OXYGEN SENSOR (HO2S) Exploded View Special Tool(s) Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the heated oxygen sensor (HO2S) electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3863 3. Using the special tool, remove the HO2S. - To install, tighten to 46 Nm (34 lb-ft). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3864 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor CATALYST MONITOR SENSOR Exploded View Special Tool(s) Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the catalyst monitor sensor electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3865 3. Using the special tool, remove the catalyst monitor sensor. - To install, tighten to 46 Nm (34 lb-ft). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch POWER STEERING PRESSURE (PSP) SWITCH Typical Power Steering Pressure (PSP) Switch The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch > Page 3870 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor POWER STEERING PRESSURE (PSP) SENSOR Typical Power Steering Pressure (PSP) Sensor The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM changes as the hydraulic pressure changes. The PCM uses the input signal from the PSP sensor to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP sensor signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback Exhaust Gas Recirculation (EGR) (DPFE) Sensor Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback Exhaust Gas Recirculation (EGR) (DPFE) Sensor DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) (DPFE) SENSOR DPFE Sensor The DPFE sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through 2 hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the DPFE sensor housing for identification (note that the HI signal uses a larger diameter hose). The DPFE sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the powertrain control module (PCM) as EGR flow rate feedback. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback Exhaust Gas Recirculation (EGR) (DPFE) Sensor > Page 3875 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback Exhaust Gas Recirculation (EGR) (DPFE) Sensor - Tube Mounted DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) (DPFE) SENSOR - TUBE MOUNTED DPFE Sensor - Tube Mounted The tube mounted DPFE sensor is identical in operation as the larger plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3879 C189 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Electronic Throttle Body (ETB) Position Sensor Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR The ETB position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB position signals are required for increased monitoring. The first ETB position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). During normal operation the negative slope ETB position sensor signal (TP1) is used by the control strategy as the indication of throttle position. The 2 ETB position sensor signals make sure the PCM receives a correct input even if 1 signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Electronic Throttle Body (ETB) Position Sensor > Page 3882 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor THROTTLE POSITION (TP) SENSOR Typical TP Sensor The TP sensor is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a 3-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page 3883 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Removal 1. Disconnect the battery ground cable. 2. Remove the air cleaner inlet pipe and the air cleaner assembly. 3. Disconnect the throttle position (TP) sensor electrical connector. 4. CAUTION: Failure to remove the TP sensor screws in the following manner will result in damage to the screws. First loosen the screws 1-2 full turns using a hand tool and then use a suitable high speed driver to complete the removal. Remove and discard the 2 screws and the TP sensor. Installation 1. CAUTION: - Do not reuse the TP sensor and screws. A new TP sensor and screws must be installed. - Do not use a high speed driver to install the new screws or damage to the TP sensor can occur. NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor is aligned with the radial locator hole on the throttle body. Position the new TP sensor and install the 2 new screws. Tighten to 3 Nm (27 lb-in). 2. Connect the TP sensor electrical connector. 3. Install the air cleaner and air cleaner inlet pipe. 4. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3887 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3890 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3891 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3892 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3893 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3894 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3895 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3896 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3897 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3898 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3899 Transmission Position Switch/Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3900 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3901 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3902 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3903 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3904 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3905 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3906 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3907 C167 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3908 Transmission Position Switch/Sensor: Adjustments 4R70E/4R75E Transmission Range (TR) Sensor Adjustment Special Tools 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual lever shift control cable. 3. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control lever nut. 2 Remove the manual control lever. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3909 4. Loosen the digital transmission range (TR) sensor bolts. 5. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 6. CAUTION: Tightening one bolt before tightening the other may cause the sensor to bind or become damaged. Using the special tool, align the digital TR sensor and tighten the bolts in an alternating sequence. ^ Tighten to 9 Nm (80 inch lbs.). 7. Install the manual control lever. ^ Position the manual control lever. 2 Install a new manual lever shaft outer nut. ^ Tighten to 33 Nm (24 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3910 8. With the manual lever in overdrive connect the shift lever control cable. 9. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3911 Transmission Position Switch/Sensor: Service and Repair 4R70E/4R75E Automatic Transmission Digital Transmission Range (TR) Sensor Special Tools Removal NOTE: Manual shift lever must be in the NEUTRAL position. 1. With the vehicle in NEUTRAL, position it on a hoist. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3912 2. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual control lever shift control cable. 3. Disconnect the digital TR electrical connector. 4. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control nut. 2 Remove the manual control lever. 5. Remove the digital TR sensor bolts and the digital TR sensor. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3913 1. Install the digital TR sensor and loosely install the bolts. 2. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 3. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. Tighten the digital TR sensor bolts. ^ Tighten to 9 Nm (80 inch lbs.). 4. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual control lever nut. ^ Tighten to 33 Nm (24 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3914 5. Connect the digital TR sensor electrical connector. 6. Connect the shift cable end to the manual lever with the lever in the (D) position. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Output Shaft Speed (OSS) Sensor Vehicle Speed Sensor: Description and Operation Output Shaft Speed (OSS) Sensor OUTPUT SHAFT SPEED (OSS) SENSOR The OSS sensor provides the PCM with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Output Shaft Speed (OSS) Sensor > Page 3919 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) VEHICLE SPEED SENSOR (VSS) Typical Vehicle Speed Sensor (VSS) The VSS is a variable reluctance or HALL-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling, and torque converter clutch scheduling. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback Exhaust Gas Recirculation (EGR) (DPFE) Sensor Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback Exhaust Gas Recirculation (EGR) (DPFE) Sensor DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) (DPFE) SENSOR DPFE Sensor The DPFE sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through 2 hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the DPFE sensor housing for identification (note that the HI signal uses a larger diameter hose). The DPFE sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the powertrain control module (PCM) as EGR flow rate feedback. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback Exhaust Gas Recirculation (EGR) (DPFE) Sensor > Page 3925 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback Exhaust Gas Recirculation (EGR) (DPFE) Sensor - Tube Mounted DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) (DPFE) SENSOR - TUBE MOUNTED DPFE Sensor - Tube Mounted The tube mounted DPFE sensor is identical in operation as the larger plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3930 C2040 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3931 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The APP sensor is an input to the powertrain control module (PCM) and is used to determine the torque demand. There are 3 pedal position signals in the sensor. Signal 1, APPS1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, APPS2 and APPS3, both have a positive slope (increasing angle, increasing voltage). During normal operation APPS1 is used as the indication of pedal position by the strategy. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. There are 2 reference voltage circuits and 2 signal return circuits for the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3935 C1454 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3936 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW (MAF) SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT Sensor Wire Where Applicable) Terminals Typical Mass Air Flow (MAF) Sensor Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3937 Typical Drop-in Mass Air Flow (MAF) Sensor The MAF sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above the ambient temperature as measured by a constant cold wire. If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the mass air flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. Most MAF sensors have integrated bypass technology (IBT) with an integrated intake air temperature (IAT) sensor. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3938 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the mass air flow (MAF) sensor electrical connector. 3. Remove the 2 bolts and the MAF sensor. - To install, tighten to 7 Nm (62 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Fuel Rail Pressure Sensor View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Fuel Rail Pressure Sensor > Page 3943 View 151-36 (Chassis, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Fuel Rail Pressure/Temperature Sensor C1475 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Fuel Rail Pressure/Temperature Sensor > Page 3946 C435 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation > Fuel Rail Pressure (FRP) Sensor Fuel Pressure Sensor/Switch: Description and Operation Fuel Rail Pressure (FRP) Sensor FUEL RAIL PRESSURE (FRP) SENSOR Fuel Rail Pressure (FRP) Sensor The FRP sensor is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and the resistance decreases as the pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation > Fuel Rail Pressure (FRP) Sensor > Page 3949 Fuel Pressure Sensor/Switch: Description and Operation Fuel Rail Pressure Temperature (FRPT) Sensor FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR Typical Fuel Rail Pressure Temperature (FRPT) Sensor The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to determine the pressure difference between the fuel rail and the intake manifold. The relationship between fuel pressure and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. Both pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation > Page 3950 Fuel Pressure Sensor/Switch: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE (FRPT) SENSOR Removal and Installation WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before 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. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel rail pressure and temperature (FRPT) sensor electrical and vacuum connectors. 4. Remove the 2 bolts and the FRPT sensor and discard the O-ring seal. - To install, tighten to 10 Nm (89 lb-in). - Install a new O-ring seal. - Lubricate the new O-ring seal prior to installation. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3954 C1475 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation > Fuel Rail Pressure Temperature (FRPT) Sensor Fuel Temperature Sensor: Description and Operation Fuel Rail Pressure Temperature (FRPT) Sensor FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR Typical Fuel Rail Pressure Temperature (FRPT) Sensor The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to determine the pressure difference between the fuel rail and the intake manifold. The relationship between fuel pressure and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. Both pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation > Fuel Rail Pressure Temperature (FRPT) Sensor > Page 3957 Fuel Temperature Sensor: Description and Operation Fuel Rail Temperature (FRT) Sensor FUEL RAIL TEMPERATURE (FRT) SENSOR Fuel Rail Temperature (FRT) Sensor The FRT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRT sensor measures the temperature of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation > Page 3958 Fuel Temperature Sensor: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE (FRPT) SENSOR Removal and Installation WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before 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. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel rail pressure and temperature (FRPT) sensor electrical and vacuum connectors. 4. Remove the 2 bolts and the FRPT sensor and discard the O-ring seal. - To install, tighten to 10 Nm (89 lb-in). - Install a new O-ring seal. - Lubricate the new O-ring seal prior to installation. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations View 151-19 (Left Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3962 C4168 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3963 Inertia Fuel Shutoff Switch: Description and Operation INERTIA FUEL SHUTOFF (IFS) SWITCH Typical Inertia Fuel Shutoff (IFS) Switch The IFS switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shutoff the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner's Literature for the location of the IFS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3964 Inertia Fuel Shutoff Switch: Service and Repair INERTIA FUEL SHUTOFF (IFS) SWITCH Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the LH rear interior quarter trim panel. 3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Remove the 2 bolts and the IFS switch. - To install, tighten to 10 Nm (89 lb-in). 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3968 C189 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Electronic Throttle Body (ETB) Position Sensor Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR The ETB position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB position signals are required for increased monitoring. The first ETB position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). During normal operation the negative slope ETB position sensor signal (TP1) is used by the control strategy as the indication of throttle position. The 2 ETB position sensor signals make sure the PCM receives a correct input even if 1 signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Electronic Throttle Body (ETB) Position Sensor > Page 3971 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor THROTTLE POSITION (TP) SENSOR Typical TP Sensor The TP sensor is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a 3-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 3972 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Removal 1. Disconnect the battery ground cable. 2. Remove the air cleaner inlet pipe and the air cleaner assembly. 3. Disconnect the throttle position (TP) sensor electrical connector. 4. CAUTION: Failure to remove the TP sensor screws in the following manner will result in damage to the screws. First loosen the screws 1-2 full turns using a hand tool and then use a suitable high speed driver to complete the removal. Remove and discard the 2 screws and the TP sensor. Installation 1. CAUTION: - Do not reuse the TP sensor and screws. A new TP sensor and screws must be installed. - Do not use a high speed driver to install the new screws or damage to the TP sensor can occur. NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor is aligned with the radial locator hole on the throttle body. Position the new TP sensor and install the 2 new screws. Tighten to 3 Nm (27 lb-in). 2. Connect the TP sensor electrical connector. 3. Install the air cleaner and air cleaner inlet pipe. 4. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1 C1366 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1 > Page 3979 C1367 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3980 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR Typical Synchronizer Hall-Effect CMP Sensor Typical Variable Reluctance CMP Sensor The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston No. 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to select the correct ignition coil to fire. Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor and the 2-pin connector variable reluctance type sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3981 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the camshaft position (CMP) sensor electrical connector. 3. Remove the bolt and the CMP sensor. Discard the O-ring seal. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3985 C101 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3986 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Typical Crankshaft Position (CKP) Sensor The CKP sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L 10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3987 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the accessory drive belt. 4. Disconnect the A/C compressor electrical connector. 5. Remove the 3 bolts and position the A/C compressor aside. - To install, tighten to 25 Nm (18 lb-ft). 6. Disconnect the crankshaft position (CKP) sensor electrical connector. 7. Remove the bolt and the CKP sensor. Discard the O-ring seal. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the new O-ring seal with clean engine oil prior to installation. 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Locations View 151-14 (Steering Column) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions Ignition Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3993 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3994 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3995 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3996 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3997 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3998 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3999 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4000 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4001 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4002 Ignition Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4003 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4004 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4005 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4006 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4007 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4008 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4009 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4010 C250 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Page 4011 Ignition Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Page 4012 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Page 4013 Ignition Switch: Service and Repair Ignition Switch Ignition Switch Removal and Installation 1. Remove the steering wheel. 2. NOTE: Lower tilt release handle to access second screw. Remove the lower steering column shroud. ^ Remove the screws. 3. NOTE: The screw is located behind the multi-function switch. Remove the screw and the upper steering column shroud. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Page 4014 4. Remove the bolt, push the release and position the multi-function switch aside. 5. Disconnect the ignition switch electrical connector. 6. Remove the ignition switch. 7. To install, reverse the removal procedure. ^ Make sure that the spring located under the ignition switch is positioned on the steering column lock rod. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 C109 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 4020 C108 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 4021 Knock Sensor: Description and Operation KNOCK SENSOR (KS) Two Types Of Knock Sensor (KS) The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 4022 Knock Sensor: Service and Repair KNOCK SENSOR (KS) Removal and Installation 1. Remove the intake manifold. 2. Disconnect the knock sensor (KS) electrical connectors. 3. Remove the 2 bolts and the 2 knock sensors. - To install, tighten to 20 Nm (15 lb-ft). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Item....................................................................................................................................................... ..............................................................Specification Fuel Pressure Key on, engine off................................................................................................................................. .............................................240-310 kPa (35-45 psi) Engine running................................................. ..................................................................................................................................193-310 kPa (28-45 psi) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Measured/PID Values Hot Idle Speed ..................................................................................................................................... ....................................................... 600-650 RPM Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 AIR CLEANER INTAKE PIPE Exploded View Removal and Installation 1. Remove the air cleaner element. 2. Reach into the opening of the air cleaner assembly and depress the locking tab on the air cleaner intake pipe to release the air cleaner intake pipe from the air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 4034 3. Remove the air cleaner intake tube assembly. 4. CAUTION: The air cleaner intake pipe should be securely sealed to prevent unusual engine noise. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair AIR CLEANER ELEMENT Exploded View Removal and Installation 1. Release the retaining clips and remove the air cleaner element tray. 2. Remove the air cleaner element from the air cleaner element tray. 3. CAUTION: The air cleaner element tray must be fully seated to the air cleaner housing. Failure to do so will result in unusual engine noise. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The electrical connector is located on the LH frame rail under the driver side door. Disconnect the electrical connector. 3. Start the engine and allow it to idle until it stalls. 4. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail pressure has been released. 5. Turn the ignition switch to the OFF position. 6. When fuel system service is complete, connect the electrical connector. 7. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 8. Install the diagnostic tool. Turn the key ON with the engine OFF. Cycle the key OFF, then ON. Select the appropriate vehicle and engine qualifier. Clear all diagnostic trouble codes (DTCs) and carry out a PCM reset. 9. Start the vehicle and check the fuel system for leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Firing order........................................................................................................................................... ......................................................... 1-3-7-2-6-5-4-8 Eight separate ignition coils: - are mounted directly above each spark plug. - are controlled by the powertrain control module (PCM) for correct firing sequence. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Item ...................................................................................................................................................... ............................................................ Specification Firing order........................................................................................................................................... ......................................................... 1-3-7-2-6-5-4-8 Eight separate ignition coils: - are mounted directly above each spark plug. - are controlled by the powertrain control module (PCM) for correct firing sequence. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions Spark Plug: Technical Service Bulletins Ignition System - Spark Plug Removal Instructions TSB 08-7-6 04/14/08 SPARK PLUG REMOVAL INSTRUCTIONS - 4.6L 3V/5.4L 3V16.8L 3V FORD: 2005-2008 Mustang 2004-2008 F-150 2005-2008 Expedition, F-Super Duty 2006-2008 Explorer, F-53 Motorhome Chassis 2007-2008 Explorer Sport Trac LINCOLN: 2005-2008 Navigator 2006-2008 Mark LT MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-1-9 to update Vehicle Applications, Service Procedure and Part List. ISSUE Some 2004-2008 F-150, 2006-2008 Mark LT, 2005-2008 F-Super Duty, Expedition, and Navigator, with 5.4L 3-V engine; 2005-2008 Mustang, 2006-2008 Explorer, Mountaineer, and 2007-2008 Explorer Sport Trac with 4.6L 3-V engine; 2005-2008 F-Super Duty, 2006-2008 and F-Stripped Chassis, with 6.8L 3-V engine may experience difficulty with spark plug removal. This may cause damage to the spark plug and leave part of the spark plug in the cylinder head. Affected engine build dates are as follows: 5.4L 3-V and 6.8L 3-V before 10/9/07, 4.6L 3-V before 11/30/07. ACTION Refer to the following Service Procedure for techniques to remove the spark plugs and extract broken spark plugs. SERVICE PROCEDURE The engine build date can be read on the left hand cam cover information sticker. To remove spark plugs without damage, it is necessary to adhere exactly to this procedure before removal is attempted. CAUTION DO NOT REMOVE PLUGS WHEN THE ENGINE IS WARM OR HOT. THE ENGINE MUST BE AT ROOM TEMPERATURE WHEN PERFORMING SPARK PLUG SERVICE. REMOVING THE SPARK PLUGS FROM A WARM/HOT ENGINE INCREASES THE CHANCE THE THREADS COULD BE DAMAGED. Spark Plug Removal Procedure 1. Remove the coil-on-plug assemblies and thoroughly blow out the spark plug wells and surrounding valve cover area with compressed air. 2. Back out the spark plugs no more than 1/8 to 1/4 of a turn. Using Motorcraft(R) Carburetor Tune-Up Cleaner, fill the spark plug well just above where the jamb nut hex sits (1/2 - 3/4 teaspoon). A minimum period of 15 minutes of soak time is required. The cleaner will wick down to the ground electrode shield and soften the carbon deposits in this time. DO NOT WORK the spark plug back and forth at this point. NOTE COMPLETELY REVIEW THE PRODUCT LABEL FOR THE MOTORCRAFT CARBURETOR TUNE-UP CLEANER PRODUCT - USE AT ROOM TEMPERATURE AND SHAKE WELL. CAUTION EXCESSIVE MOTORCRAFT(R) CARBURETOR TUNE-UP CLEANER, OR REPEATING THE PROCESS SEVERAL TIMES WITH TOO MUCH CLEANER FLUID, COULD INTRODUCE ENOUGH LIQUID VOLUME TO HYDRO-LOCK THE ENGINE. CAUTION DO NOT USE AIR OR POWER TOOLS FOR SPARK PLUG REMOVAL. SPARK PLUGS MUST ONLY BE REMOVED WITH HAND TOOLS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 4053 3. Tighten, and then loosen the spark plug, working the plug back and forth. Some screeching and high effort may be noticed. The expected removal torque is about 33 lb-ft (45 N.m). Repeat the back and forth turning as needed until turning effort is reduced, and remove the spark plugs. NOTE NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT HIGH TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD. DO NOT COAT THE ELECTRODE STRAP. (Figure 1) Separated/Broken Spark Plug Removal If the spark plug separates after following the Spark Plug Removal Procedure, it will fail in one of three modes. Refer to the appropriate removal procedure as required. a. Mode 1: The ground electrode shield is left behind as an empty shell. (Figure 2) b. Mode 2: The entire porcelain insulator and ground electrode shield remains in the cylinder head. (Figure 3) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 4054 c. Mode 3: The upper section of porcelain broke off with remaining porcelain left inside the ground shield. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 4055 Flowchart of procedure. (Figure 5) Mode 1 Procedure: Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 4056 Use Rotunda special service tool 303-1203 to remove an empty ground electrode shield from the cylinder head. (Figure 6) NOTE THIS TOOL IS ONLY DESIGNED TO WORK WITH AN EMPTY GROUND ELECTRODE SHIELD. IF PORCELAIN REMAINS, PROCEED TO MODE 2 OR 3 REMOVAL. 1. Modify vacuum cap to a 3/8" (10 mm) length for each ground electrode shield that needs to be removed. (Figure 7) 2. Use the installation rod (J) provided with service tool 303-1203 update to install the modified vacuum cap. Push the cap into the ground shield down to the electrode strap. This will plug and protect the combustion chamber from contamination. (Figure 7) 3. Thread-tap the ground electrode shield using a 9.0 x 1.0 mm plug tap (tap profile is about 3-4 reduced diameter threads on the tip end). a. Coat the end of the tap with general purpose grease. (Figure 8) b. Turn the tap about 3 to 4 turns into the ground electrode shield. Back the tap up frequently to break chips and avoid cut material from coiling-up in the spark plug well. A tap socket adaptor (K) is provided with service tool 303-1203 update to connect the tap to a 3/8" socket Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 4057 drive. CAUTION DO NOT ATTEMPT TO REMOVE THE GROUND ELECTRODE SHIELD WITH THE TAP AND WRENCH. THE TAP MAY BREAK IF THIS IS ATTEMPTED. 4. Thread Rotunda special service tool 303-1203 into the ground electrode shield. (Figure 9) a. Install the stepped end of the tool pilot bushing into the spark plug well ensuring it bottoms out. b. Screw the center shank into the ground electrode shield. Do not over tighten the shank, to prevent thread stripping. c. Install the nylon washer and jack nut until finger tight. d. Turn the jack nut until the ground electrode is freed from the cavity and withdraw the tool assembly. NOTE NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD. DO NOT COAT THE ELECTRODE STRAP. Mode 2 Procedure: 1. Add an additional 1/2 teaspoon Motorcraft® Carburetor Tune-Up Cleaner fluid into spark plug well and allow 15 minutes of soak time. 2. Using long-reach nose pliers grasp and remove the porcelain with an up and down motion taking care not to fracture the porcelain. 3. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder head. Mode 3 Procedure: CAUTION DO NOT DRIVE PORCELAIN DOWN INTO THE GROUND SHIELD WITH A PUNCH AS FRAGMENTS MAY ENTER THE COMBUSTION CHAMBER. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 4058 Use Rotunda special service tool kit 303-1398 to remove porcelain broken inside the ground electrode shield. (FIGURE 10) Porcelain Removal - Preparation CAUTION THE ENGINE AND THE BONDING ADHESIVE MUST BE ROOM TEMPERATURE OF 70 °F (21 °C) OR HIGHER FOR PROPER CURE AND BOND STRENGTH. VERIFY EXPIRATION DATE OF ADHESIVE. CAUTION DO NOT REUSE PINS. THIS ENSURES THE CORRECT SURFACE CHARACTERISTICS FOR BONDING. 1. Remove any remaining electrode material from broken porcelain with long nose reach pliers. 2. Spray Motorcraft® Metal Brake Parts Cleaner into the porcelain hole for 2-4 seconds using the straw nozzle supplied with the brake cleaner can. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 4059 3. Insert a pin (A) into the collet (B). Screw the collet onto the threaded rod (C). Install the assembled collet, pin, and threaded rod into the steel tool pilot (F). (Figures 11 and 12) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 4060 4. Retract the collet and pin into the steel tool pilot, protecting the pin. (Figures 13 and 14) NOTE PIN TIP DAMAGE OR BENT PINS WILL PREVENT INSERTION INTO THE PORCELAIN. 5. Insert the completed assembly into the spark plug well and fully engage the pin into the porcelain. (Figure 15) 6. Spray Motorcraft(R) Metal Brake Parts Cleaner 2-4 seconds between the spark plug well and steel tool pilot. The steel tool pilot must be lifted up approximately 1/2" to allow brake cleaner to flood the porcelain and pin. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 4061 7. Scrub the porcelain inside diameter by moving the threaded rod up and down vigorously. Take care making sure the pin does not disengage the porcelain. (Figure 16). 8. Repeat Steps 6 and 7. 9. Remove the tool assembly. Again flood the porcelain with Motorcraft(R) Metal Brake Parts Cleaner for 2-4 seconds, then blow out the entire spark plug well and porcelain with dry compressed air. NOTE CLEAN AND DRY COMPONENTS ARE KEY TO BONDING THE PIN TO THE PORCELAIN. 10. Repeat Steps 1-9 to prepare remaining porcelain fragments as needed. 11. Disassemble the collet and pin from the threaded rod. Dry the tools thoroughly with dry compressed air. Porcelain Removal - Bonding Process CAUTION USE CARE TO PREVENT BONDING AGENT FROM CONTACTING THREADS IN CYLINDER HEAD. NOTE WORKING TIME LIMIT OF LOCTITE(R) 638(TM) RETAINING COMPOUND IS 5 MINUTES. 1. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to opposite sides of a clean and dry applicator (H). Excessive amounts of Loctite(R) 638(TM) are being used if it drips off the applicator. (Figure 17) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 4062 2. Insert applicator into the porcelain and move applicator up and down 1/2" (13 mm) while turning to spread the Loctite® 638TM on the inside of the porcelain. (Figure 18). 3. Add additional Loctite(R) 638(TM), repeating Steps 1 and 2. 4. Clean the applicator with Motorcraft(R) Metal Brake Parts Cleaner before the bonding agent starts to cure. 5. Reassemble a dry and clean collet and pin assembly. 6. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to the pin. Excessive amounts of Loctite® 638TMare being used if it drips off the pin. 7. Retract the collet and pin into the steel tool pilot to protect the Loctite(R) 638(TM) coated pin. 8. Insert the completed assembly into spark plug well and fully engage the pin into the porcelain with a twisting motion to spread the bonding agent. 9. Add additional Loctite® 638TM, repeating Steps 6-8. 10. Leave the pin fully inserted in the porcelain while the adhesive cures. Replace the steel tool pilot with the aluminum alignment sleeve (G), Figure 9, to support the threaded rod while the adhesive cures if additional porcelain fragments are present in other cylinders. (Figure 19). CAUTION A MINIMUM 1 HOUR CURING TIME AT 70 °F (21 °C) DEGREES IS REQUIRED BEFORE EXTRACTION IS ATTEMPTED. 11. Allow the Loctite(R) 638(TM) to cure for a minimum of one hour at 70 °F (21 °C). 12. Repeat the bonding process for remaining cylinders as needed. Porcelain Removal - Extraction 1. After a minimum of one hour curing at 70 °F (21 °C), install the steel pilot tool over the threaded rod. 2. Install the washer and jack nut until finger tight against the tool pilot bushing. CAUTION ONLY THE STEEL PILOT TOOL IS ACCEPTABLE FOR USE IN PORCELAIN REMOVAL. 3. While holding the end of the threaded rod with a wrench, tighten the jack nut until the porcelain is free of the ground electrode. 4. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder head. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 4063 NOTE NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD. DO NOT COAT THE ELECTRODE STRAP. (FIGURE 7) Porcelain Removal - Pin Slipped Out In the unlikely event that the pin does not remove the broken porcelain, this process can be repeated. Key elements to success are: ^ Clean and dry porcelain ^ Sufficient Loctite® 638TM Retaining Compound spread uniformly ^ Loctite(R) 638(TM) cure time and temperature ^ Preventing the threaded rod from rotating while removing the porcelain Replacement Supplies Replacement kit components and additional kit consumables (Loctite(R) 638TM Retaining Compound and pins) can be obtained by calling 1-800-ROTUNDA, Option 5. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT080706 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 12405 01 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark Plug Gap Spark Plug Gap ............................................................................................................................................................. 0.040 - 0.050 inch (1.02 - 1.27 mm) NOTE: Spark plug gap not adjustable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 4066 Spark Plug: Specifications Spark Plug Torque Spark Plugs ......................................................................................................................................... ................................................... 34 Nm (25.0 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 4067 Spark Plug: Application and ID Spark Plug ........................................................................................................................................... ...................................................................... PZT-2F Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 4068 Spark Plug: Service and Repair SPARK PLUGS Engine Ignition - RH Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 4069 Engine Ignition - LH Exploded View Removal and Installation 1. Remove the ignition coil-on-plug. 2. NOTE: - Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs. - If an original spark plug is used, make sure it is installed in the same cylinder from which it was taken. New spark plugs can be used in any cylinder. Remove the spark plugs. To install, tighten to 34 Nm (25 lb-ft). 3. Inspect the spark plugs. Install new spark plugs as necessary. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications GENERAL SPECIFICATIONS Compression Pressure Limit Chart (Part 1) Compression Pressure Limit Chart (Part 2) The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 4073 Compression Check: Testing and Inspection Compression Test-Compression Gauge Check 1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the battery is correctly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of 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 The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart (Part 1) Compression Pressure Limit Chart (Part 2) Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 4074 Compression Test-Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications This engine is equipped with hydraulic valve lifters. No adjustment is required. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4082 C2040 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4083 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The APP sensor is an input to the powertrain control module (PCM) and is used to determine the torque demand. There are 3 pedal position signals in the sensor. Signal 1, APPS1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, APPS2 and APPS3, both have a positive slope (increasing angle, increasing voltage). During normal operation APPS1 is used as the indication of pedal position by the strategy. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. There are 2 reference voltage circuits and 2 signal return circuits for the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4087 C1454 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4088 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW (MAF) SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT Sensor Wire Where Applicable) Terminals Typical Mass Air Flow (MAF) Sensor Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4089 Typical Drop-in Mass Air Flow (MAF) Sensor The MAF sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above the ambient temperature as measured by a constant cold wire. If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the mass air flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. Most MAF sensors have integrated bypass technology (IBT) with an integrated intake air temperature (IAT) sensor. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4090 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the mass air flow (MAF) sensor electrical connector. 3. Remove the 2 bolts and the MAF sensor. - To install, tighten to 7 Nm (62 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 4094 C1454 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 4095 Intake Air Temperature Sensor: Description and Operation INTAKE AIR TEMPERATURE (IAT) SENSOR Typical Stand-Alone/Non-Integrated Intake Air Temperature (IAT) Sensors Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into A Drop-in Or Flange-type MAF Sensor The IAT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 4096 fuel, spark, and air flow. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Currently there are 2 design types of IAT sensors used, a stand-alone/non-integrated type and a integrated type. Both types function the same, however the integrated type is incorporated into the mass air flow (MAF) sensor instead of being a stand alone sensor. Supercharged vehicles use 2 IAT sensors. Both sensors are thermistor type devices and operate as described. However, one is located before the supercharger at the air cleaner for standard OBD/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations Body Control Module: Locations VEHICLE SECURITY MODULE (VSM) View 151-17 (RH A-Pillar) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Page 4100 Body Control Module: Diagrams VEHICLE SECURITY MODULE (VSM) C2113a C2113b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Page 4101 C2113c Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) Body Control Module: Service and Repair Driver Seat Module (DSM) DRIVER SEAT MODULE (DSM) Removal and Installation CAUTION: - Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. - Prior to the removal of the module, it is necessary to upload module configuration information to the appropriate diagnostic equipment. This information needs to be downloaded into the new module once installed. 1. NOTE: The module is accessed with the seat fully in the UP position. Position the driver seat module forward to remove it from the bracket. 2. Disconnect the battery. 3. Disconnect the electrical connectors and remove the DSM. 4. CAUTION: Once the module is installed it is necessary to download the module configuration information from the diagnostic tool into the new module. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 4104 Body Control Module: Service and Repair Vehicle Security Module VEHICLE SECURITY MODULE Removal CAUTION: The steps included in the vehicle security module removal and installation procedure are critical to restoring the vehicle security and tire pressure monitoring systems to normal operation. A new vehicle security module is delivered in manufacturing mode with 6 pre-set diagnostic trouble codes (DTCs) related to the tire pressure monitoring system (TPMS). The presence of these DTCs requires the installation procedures be followed in order to clear the DTCs and enable normal vehicle security module operations. 1. NOTE: Prior to the removal of the vehicle security module, it is necessary to upload the module configuration information to the diagnostic tool. This information must be downloaded to the new vehicle security module after installation. Disconnect the battery. 2. Remove the pin-type retainer and the RH A-pillar lower trim panel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 4105 3. Remove the glove compartment. 4. Disconnect the 3 electrical connectors. 5. Remove the 2 screws and the vehicle security module. Installation 1. Position the vehicle security module and install the 2 screws. - Tighten the screws to 6 Nm (53 lb-in). 2. Connect the 3 electrical connectors. 3. Position the RH A-pillar lower trim panel and install the pin-type retainer. 4. Install the glove compartment 5. Connect the battery. 6. NOTE: When successful, this step provides the calibration necessary for vehicle security module operation and clears DTC B2477. The clearing of the DTC indicates the calibration data has been successfully downloaded to the vehicle security module. Download the vehicle security module configuration information from the diagnostic tool to the vehicle security module. 7. NOTE: When successful, this step clears DTCs B2868, B2869, B2870 and B2871. The clearing of these DTCs indicates the vehicle security module has recognized the tire pressure sensors during the training procedure. Train the tire pressure sensors. 8. Clear the DTCs. 9. NOTE: - DTC C2780 will not clear if any other DTCs are present in the vehicle security module. - This step is required to clear DTC C2780, allow the vehicle security module to exit the manufacturing mode, and to be sure there are no other concerns with the newly programmed vehicle security module. Carry out the vehicle security module on-demand self-test. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Locations View 151-10 (behind Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Locations > Page 4109 C278 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Description and Operation > Brake Pedal Position (BPP) Switch Brake Signal: Description and Operation Brake Pedal Position (BPP) Switch BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - BPP switch is hardwired to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - BPP switch is hardwired to the Anti-Lock Brake System (ABS) Module, Lighting Control Module (LCM), or Rear Electronic Module (REM), the BPP signal is then broadcast over the network to be received by the PCM. - BPP switch is hardwired to the anti-lock brake system (ABS) traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Description and Operation > Brake Pedal Position (BPP) Switch > Page 4112 Brake Signal: Description and Operation Brake Pedal Switch (BPS)/Brake Deactivator Switch BRAKE PEDAL SWITCH (BPS)/BRAKE DEACTIVATOR SWITCH The BPS, also called the brake deactivator switch, is for vehicle speed control deactivation. A normally closed switch supplies battery positive voltage (B+) to the PCM when the brake pedal is not applied. When the brake pedal is applied, the normally closed switch opens and power is removed from the PCM. On some applications the normally closed BPS, along with the normally open BPP switch, are used for a brake rationality test within the PCM. The PCM misfire monitor profile learn function may be disabled if a brake switch concern occurs. If one or both brake pedal inputs to the PCM is not changing states when they were expected to, a diagnostic trouble code is set by the PCM strategy. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1 C1366 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1 > Page 4118 C1367 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 4119 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR Typical Synchronizer Hall-Effect CMP Sensor Typical Variable Reluctance CMP Sensor The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston No. 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to select the correct ignition coil to fire. Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor and the 2-pin connector variable reluctance type sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 4120 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the camshaft position (CMP) sensor electrical connector. 3. Remove the bolt and the CMP sensor. Discard the O-ring seal. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Description and Operation Clutch Switch: Description and Operation CLUTCH PEDAL POSITION (CPP) SWITCH Typical Clutch Pedal Position (CPP) Switch The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine load. The PCM uses the load information for mass air flow and fuel calculations. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4127 C101 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4128 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Typical Crankshaft Position (CKP) Sensor The CKP sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L 10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4129 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the accessory drive belt. 4. Disconnect the A/C compressor electrical connector. 5. Remove the 3 bolts and position the A/C compressor aside. - To install, tighten to 25 Nm (18 lb-ft). 6. Disconnect the crankshaft position (CKP) sensor electrical connector. 7. Remove the bolt and the CKP sensor. Discard the O-ring seal. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the new O-ring seal with clean engine oil prior to installation. 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations View 151-12 (Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4135 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4136 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4137 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4138 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4139 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4140 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4141 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4142 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4143 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4144 Data Link Connector: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4145 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4146 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4147 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4148 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4149 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4150 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4151 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4152 C251 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations > Page 4156 C1368 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations > Page 4157 Electronic Throttle Actuator: Description and Operation ELECTRONIC THROTTLE ACTUATOR CONTROL (TAC) The electronic TAC is a DC motor controlled by the PCM (requires 2 wires). The gear ratio from the motor to the throttle plate shaft is 17:1. There are 2 designs for the TAC, parallel and in-series. The parallel design has the motor under the bore parallel to the plate shaft. The motor housing is integrated into the main housing. The in-series design has a separate motor housing. Two springs are used; one is used to close the throttle (main spring) and the other is in a plunger assembly that results in a default angle when no power is applied. The force of the plunger spring is 2 times stronger than the main spring. The default angle is usually set to result in a top vehicle speed of 48 km/h (30 mph). Typically this throttle angle is 7 to 8 degrees from the hard stop angle. The closed throttle plate hard stop is used to prevent the throttle from binding in the bore (~0.75 degree). This hard stop setting is not adjustable and is set to result in less airflow than the minimum engine airflow required at idle. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation Electronic Throttle Control Module: Description and Operation TORQUE BASED ELECTRONIC THROTTLE CONTROL (ETC) Overview The torque based ETC is a hardware and software strategy that delivers an engine output torque (via throttle angle) based on driver demand (pedal position). It uses an electronic throttle body, the powertrain control module (PCM), and an accelerator pedal assembly to control the throttle opening and engine torque. The ETC system replaces the standard cable operated accelerator pedal, idle air control (IAC) valve, 3-wire throttle position sensor (TPS), and mechanical throttle body. Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque during shifts, and by calculating this desired torque, the system prevents engine lugging (low RPM and low manifold vacuum) while still delivering the performance and torque requested by the driver. It also enables many fuel economy/emission improvement technologies such as variable camshaft timing (VCT) (deliver same torque during transitions). Torque based ETC also results in less intrusive vehicle and engine speed limiting, along with smoother traction control. Other benefits of ETC are: eliminate cruise control actuators - eliminate idle air control (IAC) valve - better airflow range - packaging (no cable) - more responsive powertrain at altitude and improved shift quality It should be noted that the ETC system illuminates a powertrain malfunction indicator (wrench) on the instrument cluster when a concern is present. Concerns are accompanied by diagnostic trouble codes (DTCs) and may also illuminate the malfunction indicator lamp (MIL). Electronic Throttle Body (ETB) The ETB has the following characteristics: 1. The throttle actuator control (TAC) motor is a DC motor controlled by the PCM (requires 2-wires). The gear ratio from the motor to the throttle plate shaft is 17:1. 2. There are 2 designs: parallel and in-series. The parallel design has the motor under the bore parallel to the plate shaft. The motor housing is integrated into the main housing. The in-series design has a separate motor housing. 3. Two springs are used: one is used to close the throttle (main spring) and the other is in a plunger assembly that results in a default angle when no power is applied. This is for limp home reasons (the force of the plunger spring is 2 times stronger than the main spring). The default angle is usually set to result in a top vehicle speed of 48 km/h (30 mph) Typically this throttle angle is 7 to 8 degrees from the hard-stop angle. 4. The closed throttle plate hard stop is used to prevent the throttle from binding in the bore (~0.75 degree). This hard stop setting is not adjustable and is set to result in less airflow than the minimum engine airflow required at idle. 5. Unlike cable operated throttle bodies, the intent for the ETB is not to have a hole in the throttle plate or to use plate sealant. The hole is not required in the ETB because the required idle airflow is provided by the plate angle in the throttle body assembly. This plate angle controls idle, idle quality, and eliminates the need for an IAC valve. 6. The throttle position (TP) sensor has 2 signal circuits in the sensor for redundancy. The redundant throttle position signals are required for increased monitoring reasons. The first TP signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). During normal operation the negative slope TP signal (TP1) is used by the control strategy as the indication of throttle position. The TP sensor assembly requires 4 circuits. 5-volt reference voltage - Signal return (ground) - TP1 voltage with negative voltage slope (5-0 volts) - TP2 voltage with positive voltage slope (0-5 volts) Accelerator Pedal Position (APP) Sensors Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 4161 Electronic Throttle Body (ETB) And Accelerator Pedal Assembly The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1. There are 3 pedal position signals required for system monitoring. APP1 has a negative slope (increasing angle, decreasing voltage) and APP2 and APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. 2. There are 2 VREF circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. 2 reference voltage circuits (5 volts) - 2 signal return (ground) circuits - APP1 voltage with negative voltage slope (5-0 volts) - APP2 voltage with positive voltage slope (0-5 volts) - APP3 voltage with positive voltage slope (0-5 volts) 3. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. 4. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. A value is substituted for an incorrect signal if 2 of the 3 signals are incorrect. Electronic Throttle Control (ETC) System Strategy Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 4162 ETC System The torque based ETC strategy was developed to improve fuel economy and to accommodate variable camshaft timing (VCT). This is possible by not coupling the throttle angle to the driver pedal position. Uncoupling the throttle angle (produce engine torque) from the pedal position (driver demand) allows the powertrain control strategy to optimize fuel control and transmission shift schedules while delivering the requested wheel torque. The ETC monitor system is distributed across 2 processors within the PCM: the main powertrain control processor unit (CPU) and a monitoring processor called an enhanced-quizzer (E-Quizzer) processor. The primary monitoring function is carried out by the independent plausibility check (IPC) software, which resides on the main processor. It is responsible for determining the driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the generated torque exceeds driver demand by a specified amount, the IPC takes appropriate corrective action. ETC System Failure Mode And Effects Management (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 4163 ETC System Failure Mode And Effects Management (Part 2) Since the IPC and the main controller share the same processor, they are subject to a number of potential common failure modes. Therefore, the E-Quizzer processor was added to redundantly monitor selected PCM inputs and to act as an intelligent watchdog and monitor the performance of the IPC and the main processor. If it determines that the IPC function is impaired in any way, it takes appropriate failure mode and effects management (FMEM) actions. Electronic Throttle Monitor Operation: Electronic Throttle Monitor Operation (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 4164 Electronic Throttle Monitor Operation (Part 2) Accelerator and Throttle Position (TP) Sensor Inputs Accelerator Pedal Position (APP) Sensor Check: Accelerator Pedal Position (APP) Sensor Check Throttle Position (TP) Sensor Check: Throttle Position (TP) Sensor Check Throttle Plate Position Controller (TPPC) Outputs Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 4165 Throttle Plate Controller Check Operation The purpose of the TPPC is to maintain the throttle position at the desired throttle angle. It is a separate chip embedded in the PCM. The desired angle is communicated from the main CPU via a 312.5 Hz duty cycle (DC) signal. The TPPC interprets the duty cycle signal as follows: Less than 5% - Out of range, limp home default position. - Greater than or equal to 5% but less than 6% - Commanded default position, closed. - Greater than or equal to 6% but less than 7% - Commanded default position. Used for key-on, engine off. - Greater than or equal to 7% but less than 10% - Closed against hard-stop. Used to learn zero throttle angle position (hard-stop) after key-up. - Greater than or equal to 10% but less than or equal to 92% - Normal operation, between 0 degrees (hard-stop) and 82 degrees, 10% duty cycle equals 0 degrees throttle angle, 92% duty cycle equals 82 degrees throttle angle. - Greater than 92% but less than or equal to 96% - Wide Open Throttle, 82 to 86 degrees throttle angle. - Greater than 96% but less than or equal to 100% - Out of Range, limp home default position. The desired angle is relative to the hard-stop angle. The hard-stop angle is learned during each key-up process before the main CPU requests the throttle plate be closed against the hard-stop. The output of the TPPC is a voltage request to the H-driver (also in PCM). The H driver is capable of positive or negative voltage to the electronic throttle body motor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations View 151-1 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4171 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4172 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4173 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4174 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4175 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4176 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4177 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4178 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4179 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4180 Engine Control Module: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4181 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4182 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4183 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4184 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4185 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4186 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4187 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4188 Engine Control Module: Connector Views C175b (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4189 C175b (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4190 C175e (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4191 C175e (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4192 C175t (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4193 C175t (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Flash Electrically Erasable Programmable Read Only Memory (EEPROM) Engine Control Module: Service and Repair Flash Electrically Erasable Programmable Read Only Memory (EEPROM) FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) Description The flash electrically erasable programmable read only memory (EEPROM) is contained in an integrated circuit (IC) internal to the powertrain control module (PCM). The EEPROM contains the vehicle strategy including calibration information specific to the vehicle, and is capable of being programmed or flashed repeatedly. As part of the calibration there is an area referred to as the vehicle identification (VID) block. The VID block is programmed when installing a new PCM as described under Programming the VID Block for a Replacement PCM. Failure to carry out this procedure may generate fault code P1635 or P1639. The VID block in an existing PCM can also be tailored to accommodate various hardware or parameter changes made to the vehicle since production. Failure to carry out this procedure properly may generate fault code P1635, Tire/Axle Ratio out of Acceptable Range. An incorrect tire/axle ratio is one of the main causes for fault code P1639. This is described under Making Changes to the VID Block and also under Making Changes to the PCM Calibration. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the vehicle identification number (VIN), octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control, and 4-wheel drive electronic shift-on-the-fly (ESOF) versus manual shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported by the VID block is displayed on the diagnostic tool. When changing items in the VID block, the strategy places range limits on certain items such as tire and axle ratio. The number of times the VID block may be reconfigured is limited. When this limit is reached, the diagnostic tool displays a message indicating the need to flash the PCM again to reset the VID block. Programming can be carried out by a local Ford dealer or any non-Ford facility. Refer to the diagnostic tool manufacturer's instruction manual for details. Programming the VID Block for a Replacement PCM A new PCM contains the latest strategy and calibration level for a particular vehicle. However, the VID block is blank and will need programming. There are 2 procedures available. The first is an automatic data transfer from the old PCM to the new PCM, and the second is manual data entry into the new PCM. Automatic data transfer is carried out if the old PCM is capable of communicating. This is done by the use of a diagnostic tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can then be downloaded to the new PCM after it has been installed. Manual data entry must be carried out if the old module is damaged or incapable of communicating. Remove and install a new PCM. Using a compatible diagnostic tool, select and carry out the module/parameter programming, referring to the diagnostic tool manufacturer's instruction manual. Make certain that all parameters are included. Failure to properly program tire size in revolutions per mile, (rev/mile equals 63,360 divided by the tire circumference in inches), axle ratio, 4x4/4x2, and/or MSOF/ESOF may result in codes P1635 and P1639. You may be instructed to contact the As-Built Data Center for the information needed to manually update the VID block with the diagnostic tool. Contact the center only if the old PCM cannot be used or the data is corrupt. For Ford and L-M technicians, contact your National Hotline or the Professional Technician Society (PTS) website for As-Built data listed under the Service Publications Index. Non-Ford technicians use the Motorcraft(R) website at www.motorcraft.com. From the Motorcraft(R) homepage, use the search function to find the Module Programming or As-Built Data. For Ford and L-M technicians, check the Programmable Module Installation link on the PTS website for quick Programmable Module data information by vehicle when using the worldwide diagnostic system (WDS) or New Generation STAR (NGS). Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate the vehicle hardware. Refer to PCM/Module Reprogramming on the diagnostic tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM needs to be completely reprogrammed. This is due to changes made to the strategy or calibration after production, or the need to reset the VID block because it has reached its limit. Refer to PCM/Module Reprogramming on the diagnostic tool. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Flash Electrically Erasable Programmable Read Only Memory (EEPROM) > Page 4196 Engine Control Module: Service and Repair Removal and Installation POWERTRAIN CONTROL MODULE (PCM) Special Tool(s) Special Tool(s) Removal and Installation 1. NOTE: Refer to Computers and Control Systems for correct worldwide diagnostic system (WDS) hook-up procedure. If servicing the powertrain control module (PCM), connect the diagnostic tool to the vehicle. Allow the diagnostic tool to identify the vehicle and obtain configuration data. All programmable module information will automatically be retrieved by the WDS. 2. Disconnect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Flash Electrically Erasable Programmable Read Only Memory (EEPROM) > Page 4197 3. Disconnect the PCM electrical connectors. 4. Remove the 4 bolts and the PCM. - To install, tighten to 7 Nm (62 lb-in). 5. If servicing the PCM bracket, remove the 3 bolts and the PCM bracket. - To install, tighten to 10 Nm (89 lb-in). 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 4201 C107 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > CHT Sensor Engine Temperature Sensor: Description and Operation CHT Sensor The CHT sensor: ^ is mounted into the wall of the cylinder head and is not connected to any coolant passages. ^ sends the PCM a signal indicating cylinder head temperature. ^ if the temperature exceeds approximately 121 °C (250°F), the PCM disables half of the fuel injectors at a time. The PCM will alternate which fuel injectors are disabled every 32 engine cycles. The cylinders that are not being fuel injected act as air pumps to aid in engine cooling. ^ if the temperature exceeds approximately 166°C (330°F), the PCM disables all of the fuel injectors until the engine temperature drops below approximately 1 54°C (31 0°F). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > CHT Sensor > Page 4204 Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical Cylinder Head Temperature (CHT) Sensor The CHT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. The CHT sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM initiates a fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern such as low coolant or coolant loss could cause an overheating condition. As a result damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > Page 4205 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR Removal and Installation 1. Remove the intake manifold. 2. Disconnect the cylinder head temperature (CHT) sensor jumper harness electrical connector. 3. Remove and discard the CHT sensor. - To install, tighten to 10 Nm (89 lb-in). - Coat the CHT sensor threads with high temperature nickel anti-seize lubricant prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation FUEL LEVEL INPUT (FLI) NOTE: The Ford GT uses a piezoelectric sonar type fuel level sensor. The sensor is located in the tank and the sensor signal is provided as a communications network message by the instrument cluster to the PCM. The FLI is either a hard wire signal input to the PCM from the fuel pump (FP) module or a communications network message. Most vehicle applications use a potentiometer type FLI sensor connected to a float in the FP module to determine fuel level. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 4209 Fuel Level Sensor: Service and Repair FUEL PUMP MODULE Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 4210 Part 2 Exploded View Special Tool(s) Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 4211 Removal and Installation WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. 1. Remove the fuel tank. 2. Disconnect the fuel and vapor tubes from the fuel pump module. 3. Using the special tool, remove the fuel pump lock ring. 4. CAUTION: Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 4212 - Note the location of the fuel pump alignment tabs. - Carefully remove the fuel pump assembly to avoid damaging the fuel level sensor. Remove the fuel pump module assembly. Remove and discard the O-ring seal. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE (FTP) SENSOR Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The FTP sensor or in-line FTP sensor is used to measure the fuel tank pressure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Page 4216 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR Removal and Installation 1. Remove the fuel tank. 2. Disconnect the fuel vapor tube quick connect couplings from the fuel vapor/grade vent valves. 3. Disconnect the fuel vapor tube quick connect couplings from the fuel pump module. 4. Remove the fuel pressure sensor tube assembly. 5. To install, reverse the removal procedure. - Leak test the system. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Evaporative Emission System Leak Test - Carry out the evaporative emission repair verification drive cycle. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Evaporative Emission Repair Verification Drive Cycle Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation Idle Speed/Throttle Actuator - Electronic: Description and Operation IDLE AIR CONTROL (IAC) VALVE NOTE: The IAC valve assembly is not adjustable and cannot be cleaned, also some IAC valves are normally open and others are normally closed. Some IAC valves require engine vacuum to operate. The IAC valve assembly controls the engine idle speed and provides a dashpot function. The IAC valve assembly meters intake air around the throttle plate through a bypass within the IAC valve assembly and throttle body. The PCM determines the desired idle speed or bypass air and signals the IAC valve assembly through a specified duty cycle. The IAC valve responds by positioning the IAC valve to control the amount of bypassed air. The PCM monitors engine RPM and increases or decreases the IAC duty cycle in order to achieve the desired RPM. The PCM uses the IAC valve assembly to control: - no touch start - cold engine fast idle for rapid warm-up - idle (corrects for engine load) - stumble or stalling on deceleration (provides a dashpot function) - over-temperature idle boost Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4224 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4225 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4226 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4227 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4228 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4229 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4230 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4231 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4232 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4233 Information Bus: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4234 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4235 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4236 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4237 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4238 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4239 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4240 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4241 Information Bus: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 14-1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4242 14-2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4243 14-3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4244 14-4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4245 14-5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4246 14-6 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. See: Diagrams/Components/Component Location Views Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 4247 Information Bus: Description and Operation COMMUNICATIONS NETWORK Anti-Lock Brake System (ABS) Module The ABS module uses the high speed controller area network (CAN). The ABS module controls the brake pressure to the 4 wheels to keep the vehicle under control while braking. Restraints Control Module (RCM) The RCM communicates on the international standards organization (ISO) 9141 communications network. The RCM controls the deployment of the air bags based on sensor input. Vehicle Security Module The vehicle security module uses the medium speed CAN. The vehicle security module controls a variety of systems: exterior lamps - interior lamps - lock functions - monitors the entry doors and radio - perimeter security - power windows - remote keyless entry (RKE)/keyless entry - tire pressure monitoring system (TPMS) - warning chimes - windshield wipers Powertrain Control Module (PCM) The PCM communicates on the high speed CAN. The PCM controls the engine for better fuel economy, emissions control, failure mode detection and storage. The PCM also controls 4x4 functionality. Electronic Automatic Temperature Control (EATC) Module The EATC module uses the medium speed CAN. The EATC module controls automatic climate functions that maintain the vehicle interior temperature at a constant setting. Driver Seat Module (DSM) The DSM uses the medium speed CAN. The DSM controls the positioning and programming of the driver seat, pedals and both outside mirrors. Parking Aid Module The parking aid module uses the ISO 9141 communications network (Expedition only), or the medium speed CAN (Navigator only). The module controls sensors in the rear bumper that detect close objects when the transmission is in REVERSE. Transmission Control Module (TCM) The TCM uses the high speed CAN (Navigator only). The TCM controls transmission shifting, the electronic pressure control, and the torque converter clutch. Instrument Cluster The instrument cluster uses the medium speed CAN. The instrument cluster also uses the high speed CAN to communicate with other modules. It is an analog face cluster with a digital odometer. The instrument cluster displays a variety of information. Power Liftgate Module The power liftgate module uses the medium speed CAN (Navigator only). The module controls the motor that opens and closes the liftgate. Air Suspension Control Module The air suspension control module uses the medium speed CAN. The air suspension control module 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 on 4-wheel air suspension systems, or rear height sensors on the rear-wheel suspension systems. The module controls vehicle height adjustments by monitoring 2 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. Climate Controlled Seat Module The climate controlled seat module uses the medium speed CAN. The climate controlled seat module controls the temperature of the driver and passenger seats. Navigation System Module The navigation module is on the SCP communications network (Navigator only). The navigation system module controls the global positioning system on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network Information Bus: Testing and Inspection Module Communications Network Principles of Operation PRINCIPLES OF OPERATION The vehicle has 4 module communications networks: - the standard corporate protocol (SCP) communications network (Navigator with navigation system only) - the international standards organization (ISO) 9141 communications network - the medium speed controller area network (CAN) - the high speed CAN The diagnostic tool connects to all 4 networks through the data link connector (DLC). This makes diagnosis and testing of these systems easier by allowing one diagnostic tester to be able to diagnose and control any module on the 4 networks from one connector. The DLC can be found under the instrument panel between the steering column and the audio unit. Standard Corporate Protocol (SCP) Communications Network The SCP communications network (Navigator with navigation system only) remains operational even with the severing of one of the SCP communications network circuits. Communications also continue if one of the SCP communications network circuits are shorted to ground or voltage, or if some but not all termination resistors are lost. The SCP communications network allows inter-module communication. International Standards Organization (ISO) 9141 Communications Network The ISO 9141 communications network is a single circuit communications network, circuit 70 (LB/WH). The restraint control module (RCM) and the parking aid module (Expedition only) are located on the ISO 9141 communication network. The ISO 9141 communications network does not permit intermodule communication. When the diagnostic tool communicates to modules on the ISO 9141 communications network, the diagnostic tool must request all information, or initiate module commands. The ISO 9141 communications network does not function if the circuit is shorted to ground or battery voltage. Also, if one of the modules on the ISO 9141 communications network loses power or shorts internally, communications to that module fail. Medium Speed Controller Area Network (CAN) The medium speed CAN has an unshielded twisted pair cable, data plus circuit 2180 (WH/BK) and data minus, circuit 2181 (BK/YE). The medium speed CAN is used for the air suspension control module, the climate controlled seat module, the driver seat module (DSM), the electronic automatic temperature control (EATC) module, the instrument cluster, the parking aid module (Navigator only), power liftgate module, and the vehicle security module communications. The medium speed CAN is not designed to operate under single point fault conditions. If either circuit is shorted to voltage or CAN data plus is shorted to ground, module-to-module and module-to-tester communication is not possible. If CAN data minus is shorted to ground or an open exists on either bus line, module-to-module and module-to-tester communication is marginal at best. The CAN bus may remain operational when one of the two termination resistors are not present. High Speed Controller Area Network (CAN) The high speed CAN has an unshielded twisted pair cable, data plus circuit 1814 (WH/LB) and data minus circuit 1815 (PK/LB). The high speed CAN is a high speed communications network used for the anti-lock brake system (ABS) module, the instrument cluster, the transmission control module (TCM) and the powertrain control module (PCM) communication. The high speed CAN is not designed to operate under single point fault conditions. If either circuit is shorted to voltage or CAN data plus is shorted to ground, module-to-module and module-to-tester communication is not possible. If CAN data minus is shorted to ground or an open exists on either bus line, module-to-module and module-to-tester communication is marginal at best. The CAN bus may remain operational when one of the two termination resistors are not present. Inspection and Verification INSPECTION AND VERIFICATION 1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical or electrical damage. VISUAL INSPECTION CHART Electrical Central junction box (CJB) fuse 41 (20A) - Wiring harness - Connections 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the cause is not visually evident, connect the diagnostic tool to the data link connector (DLC) and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: check that the program card is correctly installed. - check the connections to the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4250 - check the ignition switch position. 5. If the diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool operating manual. 6. GO to Pinpoint Test PC. See: Pinpoint Tests/Pinpoint Test PC (Precheck) U0073-U1900 Pinpoint Test PC (Precheck) PINPOINT TEST PC: DATA LINK DIAGNOSTICS NETWORK TEST PC1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4251 Test A: The Anti-Lock Brake System (ABS) Module Does Not Respond To The Diagnostic Tool PINPOINT TEST A: THE ANTI-LOCK BRAKE SYSTEM (ABS) MODULE DOES NOT RESPOND TO THE DIAGNOSTIC TOOL A1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4252 A2-A3 Normal Operation The ABS module communicates with the diagnostic tool through the high speed controller area network (CAN), circuits 1814 (WH/LB) and 1815 (PK/LB). Check the high speed CAN circuits 1814 (WH/LB) and 1815 (PK/LB) between the ABS module C135 and the data link connector (DLC) C251. The total resistance values must not be more than 5 ohms. If the resistance is more than 5 ohms there is an open in one of the CAN circuits, damage to the DLC C251, damage to the ABS module C135, or a problem in an in-line connector. Possible Causes - high speed CAN circuit 1814 (WH/LB) open - high speed CAN circuit 1815 (PK/LB) open - ABS module - ABS module C135 Test B: The Restraint Control Module (RCM) Does Not Respond To The Diagnostic Tool PINPOINT TEST B: THE RESTRAINT CONTROL MODULE (RCM) DOES NOT RESPOND TO THE DIAGNOSTIC TOOL Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4253 B1-B2 B3 Normal Operation The restraint control module (RCM) communicates with the diagnostic tool through the international standards organization (ISO) 9141 communications network, circuit 70 (LB/WH). Check circuit 70 (LB/WH) between the RCM C310a and the data link connector (DLC) C251. The total resistance value must not be more than 5 ohms. If the resistance is more than 5 ohms there is an open in the ISO 9141 communications network circuit, damage to the DLC C251, damage to the RCM C310a, or a problem in an in-line connector. Possible Causes - ISO 9141 circuit 70 (LB/WH) open - RCM - RCM C310a Test C: The Vehicle Security Module Does Not Respond To The Diagnostic Tool PINPOINT TEST C: THE VEHICLE SECURITY MODULE DOES NOT RESPOND TO THE DIAGNOSTIC TOOL Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4254 C1 C2-C3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4255 Normal Operation The vehicle security module communicates with the diagnostic tool through the medium speed controller area network (CAN), circuits 2180 (WH/BK) and 2181 (BK/YE). Check circuits 2180 (WH/BK) and 2181 (BK/YE) between the vehicle security module C2113c and the data link connector (DLC) C251. The total resistance values must not be more than 5 ohms. If the resistance is more than 5 ohms there is an open in one of the medium speed CAN circuits, damage to the DLC C251, damage to the vehicle security module C2113c, or a problem in an in-line connector. Possible Causes - medium speed CAN circuit 2180 (WH/BK) open - medium speed CAN circuit 2181 (BK/YE) open - vehicle security module - vehicle security module C2113c Test D: The Powertrain Control Module (PCM) Does Not Respond To The Diagnostic Tool PINPOINT TEST D: THE POWERTRAIN CONTROL MODULE (PCM) DOES NOT RESPOND TO THE DIAGNOSTIC TOOL D1-D2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4256 D2-D3 Normal Operation The PCM communicates with the diagnostic tool through the high speed controller area network (CAN), circuits 1814 (WH/LB) and 1815 (PK/LB). Check the high speed CAN circuits 1814 (WH/LB) and 1815 (PK/LB) between the PCM C175b and the data link connector (DLC) C251. The total resistance values must not be more than 5 ohms. If the resistance is more than 5 ohms there is an open in one of the CAN circuits, damage to the DLC C251, damage to the PCM C175b, or a problem in an in-line connector. Possible Causes - high speed CAN circuit 1814 (WH/LB) open - high speed CAN circuit 1815 (PK/LB) open - PCM - PCM C175b Test E: The Electronic Automatic Temperature Control (EATC) Module Does Not Respond To The Diagnostic Tool PINPOINT TEST E: THE ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC) MODULE DOES NOT RESPOND TO THE DIAGNOSTIC TOOL Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4257 E1-E3 Normal Operation The EATC module communicates with the diagnostic tool through the medium speed controller area network (CAN), circuits 2180 (WH/BK) and 2181 (BK/YE). Check circuits 2180 (WH/BK) and 2181 (BK/YE) between the EATC C228b and the data link connector (DLC) C251. The total resistance values must not be more than 5 ohms. If the resistance is more than 5 ohms there is an open in one of the medium speed CAN circuits, damage to the DLC C251, damage to the EATC C228b, or a problem in an in-line connector. Possible Causes - medium speed CAN circuit 2180 (WH/BK) open Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4258 - medium speed CAN circuit 2181 (BK/YE) open - EATC module - EATC module C228b Test F: The Driver Seat Module (DSM) Does Not Respond To The Diagnostic Tool PINPOINT TEST F: THE DRIVER SEAT MODULE (DSM) DOES NOT RESPOND TO THE DIAGNOSTIC TOOL F1-F2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4259 F2-F3 Normal Operation The DSM communicates with the diagnostic tool through the medium speed controller area network (CAN), circuits 2180 (WH/BK) and 2181 (BK/YE). Check circuits 2180 (WH/BK) and 2181 (BK/YE) between the DSM C341c and the data link connector (DLC) C251. The total resistance values must not be more than 5 ohms. If the resistance is more than 5 ohms there is an open in one of the medium speed CAN circuits, damage to the DLC C251, damage to the DSM C341c, or a problem in an in-line connector. Possible Causes - medium speed CAN circuit 2180 (WH/BK) open - medium speed CAN circuit 2181 (BK/YE) open - DSM - DSM C341c Test G: The Parking Aid Module Does Not Respond To The Diagnostic Tool PINPOINT TEST G: THE PARKING AID MODULE DOES NOT RESPOND TO THE DIAGNOSTIC TOOL Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4260 G1-G3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4261 G3-G4 Normal Operation The Navigator parking aid module communicates with the diagnostic tool through the medium speed controller area network (CAN), circuits 2180 (WH/BK) and 2181 (BK/YE). The Expedition parking aid module communicates with the diagnostic tool through the international standards organization (ISO) 9141 communications network, circuit 70 (LB/WH). Check the communication circuits between the parking aid module C4226 (Expedition) or C4014b (Navigator) and the data link connector (DLC) C251. The total resistance values must not be more than 5 ohms. If the resistance is more than 5 ohms there is an open in one of the communication network circuits, damage to the DLC C251, damage to the parking aid module connectors, or a problem in an in-line connector. Possible Causes - ISO 9141 circuit 70 (LB/WH) open (Expedition only) - medium speed CAN circuit 2180 (WH/BK) open (Navigator only) - medium speed CAN circuit 2181 (BK/YE) open (Navigator only) - parking aid module - parking aid module C4226 (Expedition) or C4014b (Navigator) Test H: The Transmission Control Module (TCM) Does Not Respond To The Diagnostic Tool PINPOINT TEST H: THE TRANSMISSION CONTROL MODULE (TCM) DOES NOT RESPOND TO THE DIAGNOSTIC TOOL Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4262 H1-H3 Normal Operation The TCM communicates with the diagnostic tool through the high speed controller area network (CAN), circuits 1814 (WH/LB) and 1815 (PK/LB). Check the high speed CAN circuits 1814 (WH/LB) and 1815 (PK/LB) between the TCM C1473 and the data link connector (DLC) C251. The total resistance values must not be more than 5 ohms. If the resistance is more than 5 ohms there is an open in one of the CAN circuits, damage to the DLC C251, damage to the TCM C1473, or a problem in an in-line connector. Possible Causes - high speed CAN circuit 1814 (WH/LB) open - high speed CAN circuit 1815 (PK/LB) open Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4263 - TCM - TCM C1473 Test I: The Instrument Cluster Does Not Respond To The Diagnostic Tool PINPOINT TEST I: THE INSTRUMENT CLUSTER DOES NOT RESPOND TO THE DIAGNOSTIC TOOL I1-I2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4264 I2-I3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4265 I4 Normal Operation The instrument cluster communicates with the diagnostic tool through both the high speed controller area network (CAN), circuits 1814 (WH/LB) and 1815 (PK/LB) and the medium speed CAN, circuits 2180 (WH/BK) and 2181 (BK/YE). Check both sets of CAN circuits between the instrument cluster C220b and the data link connector (DLC) C251. The total resistance values must not be more than 5 ohms. If the resistance is more than 5 ohms there is an open in one of the CAN circuits, damage to the DLC C251, damage to the instrument cluster C220b, or a problem in an in-line connector. Possible Causes - high speed CAN circuit 1814 (WH/LB) open - high speed CAN circuit 1815 (PK/LB) open - medium speed CAN circuit 2180 (WH/BK) open - medium speed CAN circuit 2181 (BK/YE) open - instrument cluster - instrument cluster C220b Test J: The Power Liftgate Module Does Not Respond To The Diagnostic Tool PINPOINT TEST J: THE POWER LIFTGATE MODULE DOES NOT RESPOND TO THE DIAGNOSTIC TOOL J1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4266 J2-J3 Normal Operation The power liftgate module communicates with the diagnostic tool through the medium speed controller area network (CAN), circuits 2180 (WH/BK) and 2181 (BK/YE). Check circuits 2180 (WH/BK) and 2181 (BK/YE) between the power liftgate module C4174d and the data link connector (DLC) C251. The total resistance values must not be more than 5 ohms. If the resistance is more than 5 ohms there is an open in one of the medium speed CAN circuits, damage to the DLC C251, damage to the power liftgate module C4174d, or a problem in an in-line connector. Possible Causes - medium speed CAN circuit 2180 (WH/BK) open - medium speed CAN circuit 2181 (BK/YE) open - power liftgate module - power liftgate module C4174d Test K: The Air Suspension Control Module Does Not Respond To The Diagnostic Tool PINPOINT TEST K: THE AIR SUSPENSION CONTROL MODULE DOES NOT RESPOND TO THE DIAGNOSTIC TOOL Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4267 K1-K2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4268 K2-K3 Normal Operation The air suspension control module communicates with the diagnostic tool through the medium speed controller area network (CAN), circuits 2180 (WH/BK) and 2181 (BK/YE). Check circuits 2180 (WH/BK) and 2181 (BK/YE) between the air suspension control module C2324b (Expedition) or C2131b (Navigator) and the data link connector (DLC) C251. The total resistance values must not be more than 5 ohms. If the resistance is more than 5 ohms there is an open in one of the medium speed CAN circuits, damage to the DLC C251, damage to the air suspension control module C2324b (Expedition) or C2131b (Navigator), or a problem in an in-line connector. Possible Causes - medium speed CAN circuit 2180 (WH/BK) open - medium speed CAN circuit 2181 (BK/YE) open - air suspension control module - air suspension control module C2324b (Expedition only) - air suspension control module C2131b (Navigator only) Test L: The Climate Controlled Seat Module Does Not Respond To The Diagnostic Tool PINPOINT TEST L: THE CLIMATE CONTROLLED SEAT MODULE DOES NOT RESPOND TO THE DIAGNOSTIC TOOL Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4269 L1-L2 L3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4270 Normal Operation The climate controlled seat module communicates with the diagnostic tool through the medium speed controller area network (CAN), circuits 2180 (WH/BK) and 2181 (BK/YE). Check circuits 2180 (WH/BK) and 2181 (BK/YE) between the climate controlled seat module C3265b and the data link connector (DLC) C251. The total resistance values must not be more than 5 ohms. If the resistance is more than 5 ohms there is an open in one of the medium speed CAN circuits, damage to the DLC C251, damage to the climate controlled seat module C3265b, or a problem in an in-line connector. Possible Causes - medium speed CAN circuit 2180 (WH/BK) open - medium speed CAN circuit 2181 (BK/YE) open - climate controlled seat module - climate controlled seat module C3265b Test M: The Navigation System Module Does Not Respond To The Diagnostic Tool PINPOINT TEST M: THE NAVIGATION SYSTEM MODULE DOES NOT RESPOND TO THE DIAGNOSTIC TOOL M1-M2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4271 M3-M4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4272 M4-M5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4273 M6 Normal Operation The navigation system module communicates with the diagnostic tool through the standard corporate protocol (SCP) communication network, circuits 914 (TN/OG) and 915 (PK/LB). Check circuits 914 (TN/OG) and 915 (PK/LB) between the navigation system module C2279a and the data link connector (DLC) C251. The total resistance values must not be more than 5 ohms. If the resistance is more than 5 ohms there is an open in one of the SCP communications circuits, damage to the DLC C251, damage to the navigation system module C2279a, or a problem in an in-line connector. Possible Causes - SCP communication network, circuits 914 (TN/OG) open - SCP communication network, circuits 915 (PK/LB) open - navigation system module - navigation system module C2279a Test N: No International Standards Organization (ISO) 9141 Communications Network Communication PINPOINT TEST N: NO INTERNATIONAL STANDARDS ORGANIZATION (ISO) 9141 COMMUNICATIONS NETWORK COMMUNICATION N1-N2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4274 N2-N4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4275 N4-N7 Normal Operation The restraint control module (RCM), and the parking aid module (if equipped) communicate with the diagnostic tool through the ISO 9141 communications network, circuit 70 (LB/WH). Check circuit 70 (LB/WH) between the RCM C310a, parking aid module C4226 and the data link connector (DLC) C251. The total resistance value must not be more than 5 ohms. If the resistance is more than 5 ohms there is an open in the ISO 9141 communications network circuit, damage to the DLC C251, damage to the RCM or parking aid module connector, or a problem in an in-line connector. Possible Causes - ISO 9141 communications network circuit 70 (LB/WH) open, short to ground, or short to voltage - DLC C251 - RCM - RCM C310a - parking aid module Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4276 - parking aid module C4226 Test O: No High Speed Controller Area Network (CAN) Communication PINPOINT TEST O: NO HIGH SPEED CONTROLLER AREA NETWORK (CAN) COMMUNICATION O1-O3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4277 O3-O4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4278 O4-O5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4279 O6-O7 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4280 O8-O11 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4281 O12-O14 O15 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4282 Normal Operation The high speed CAN has an unshielded twisted pair cable, circuits 1814 (WH/LB) and 1815 (PK/LB). The powertrain control module (PCM), instrument cluster, the anti-lock brake system (ABS) module, and the transmission control module (TCM) are all on the high speed CAN. The total resistance values from the data link connector (DLC) C251 must not be more than 5 ohms. If the resistance is more than 5 ohms there is an open in one of the CAN circuits, damage to the DLC C251, damage to one of the communications network module connectors, or damage to an in-line connector. Possible Causes - high speed CAN circuit 1814 (WH/LB) open, short to ground, or short to voltage - high speed CAN circuit 1815 (PK/LB) open, short to ground, or short to voltage - DLC C251 - PCM - PCM C175b - instrument cluster - instrument cluster C220b - ABS module - ABS module C135 - TCM - TCM C1473 (if equipped) Test P: No Medium Speed Controller Area Network (CAN) Communication PINPOINT TEST P: NO MEDIUM SPEED CONTROLLER AREA NETWORK (CAN) COMMUNICATION Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4283 P1-P3 P3-P4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4284 P5-P6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4285 P6-P7 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4286 P8-P9 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4287 P9-P10 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4288 P10-P11 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4289 P12-P14 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4290 P15-P19 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4291 P20-P23 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4292 P24-P27 Normal Operation The medium speed CAN has an unshielded twisted pair cable, circuits 2180 (WH/BK) and 2181 (BK/YE). The modules listed below all communicate with the diagnostic tool using the medium speed CAN. The total resistance values from the data link connector (DLC) C251 to an individual module must not be more than 5 ohms. If the resistance is more than 5 ohms there is an open in one of the medium speed CAN circuits, damage to the DLC C251, damage to one of the communications network module connectors, or damage to an in-line connector. Possible Causes - medium speed CAN circuit 2180 (WH/BK) open, short to ground, or short to voltage - medium speed CAN circuit 2181 (BK/YE) open, short to ground, or short to voltage - DLC C251 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4293 - air suspension control module - air suspension control module C2131b (Navigator) or C2324b (Expedition) (if equipped) - climate controlled seat module - climate controlled seat module C3265b - driver seat module (DSM) - DSM C341c - electronic automatic temperature control (EATC) module - EATC module C228b - instrument cluster - instrument cluster C220b - parking aid module (if equipped) - parking aid module C4226 (Expedition) or C4014b (Navigator) - power liftgate module (if equipped) - power liftgate module C4174d - vehicle security module - vehicle security module C2113c Test Q: No Module/Network Communication - No Power To The Diagnostic Tool PINPOINT TEST Q: NO MODULE/NETWORK COMMUNICATION - NO POWER TO THE DIAGNOSTIC TOOL Q1-Q3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4294 Q4 Normal Operation The diagnostic tool connects to the data link connector (DLC) C251 to communicate with the high speed controller area network (CAN), medium speed CAN, international standards organization (ISO) 9141 communications network and the standard corporate protocol (SCP) communication network. If communication can not be established, the diagnostic tool and the DLC C251 must be checked for damage. If the diagnostic tool and the DLC C251 are OK, ground circuits 570 (BK/WH), 875 (BK/LB) and voltage circuit 40 (LB/WH) must be checked for an open condition. Possible Causes - DLC C251 - fuse - diagnostic tool - circuit 40 (LB/WH) open - circuit 570 (BK) open - circuit 875 (BK/LB) open Symptom Chart (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4295 Symptom Chart (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4296 Symptom Chart (Part 3) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4297 Information Bus: Testing and Inspection Module Configuration Principles of Operation PRINCIPLES OF OPERATION Definition of Terms Calibration update: Some modules are designed to be flashed or reflashed with complete new software packages. This process of reflashing the module is a calibration update. Programmable parameters: These are options contained within the existing software. These include items such as tire size, customer preference items and anti-theft options. The current settings are downloaded from an existing module then uploaded to a new module. They can also be configured using the diagnostic tool. Programming the parameters is different from updating calibrations as no software is changed, only the options already contained in the software. Some modules must be programmed as part of the repair procedure. If this procedure is not followed the module does not function correctly and may set a number of diagnostic trouble codes (DTCs), including B2477 or P1639, which indicate that some necessary data has not been programmed into the module. Modules that need programming should not be exchanged between vehicles. In most cases the parameter values or settings are unique to that vehicle, and if not set correctly cause concerns or faults. The WDS automatically attempts to retrieve the module configuration information from all modules. If the module does not contain correct information, the diagnostic tool either requests As Built data or displays a list of items needed to manually configure the module. The diagnostic tool programs the module based on the data entered. For additional WDS/diagnostic tool programming procedures, refer to Programmable Module Installation. There are 3 different methods that are used for module programming: programmable module installation (PMI) - calibration update - programmable parameters Some modules do not support all 3 methods. PMI The PMI method is used when a new programmable module is installed on the vehicle. It is no longer necessary to command the diagnostic tool to gather module option content from the old module. The diagnostic tool automatically obtains any available module option content information from the old module during the vehicle ID routine that runs when the diagnostic tool is initially connected to the vehicle. It is important that you connect the WDS to the vehicle and allow it to identify the vehicle and obtain configuration data prior to removing any modules. Calibration Update Calibration update is used to install a new calibration and strategy into a module. Programmable Parameters If a module that has been modified using programmable parameters needs to be installed, the PMI procedure maintains the parameters in their altered state if the WDS is able to communicate with the old module during vehicle ID. Otherwise, it may be necessary to use programmable parameters to return the parameters to the altered state. Vehicle Identification (VID) Block Some powertrain control modules (PCMs) contain a memory area called a VID block. The PCM VID block may contain the factory settings for the configurable modules unless the PCM is flashed with a new calibration, in which case some PCM parameters may be modified. As-Built Data Center The As-Built Data Center maintains a record of the vehicle configuration in a database. The vehicle identification number (VIN) is required to obtain this information. The As-Built Data Center records the applicable module configurations stored in each module before the vehicle leaves the factory. The As-Built Data Center always reflects the original build of the vehicle as it left the factory. Only contact the As-Built Data Center when directed to do so by the diagnostic tool. Inspection and Verification INSPECTION AND VERIFICATION Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Module Communications Network > Page 4298 1. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical Wiring harness - Connectors Configurable Modules The vehicle contains the following modules that are configurable: anti-lock brake system (ABS) module - driver seat module (DSM) - dual automatic temperature control (DATC) module - instrument cluster - navigation system module - powertrain control module (PCM) - power liftgate module - temperature-controlled seat module - vehicle dynamics module - vehicle security module Programmable Parameters Index Programmable Parameters Index Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Page 4299 Information Bus: Service and Repair PROGRAMMABLE MODULE INSTALLATION Worldwide Diagnostic System (WDS) Special Tool(s) Using the Vehicle Communication Module (VCM) When the Original Body Chassis Electrical Module is Not Available 1. Install the new module. 2. Using the VCM and the latest version of the service function card, SELECT: Programmable Module Installation. 3. Select the module being installed. 4. Follow the on-screen instructions. 5. SELECT: Retrieve Module Configuration - Old ECU and press trigger. 6. Follow the on-screen instructions. 7. The VCM attempts to retrieve the module data. - If the module data is available, go to Step A. - If the VCM displays: Call As-Built Data Center, go to Step B. Step A 1. SELECT: Restore Configuration - New ECU. Press trigger. 2. The VCM completes loading the retrieved data and displays Module Download Successful. 3. Test the module for correct operation. Step B 1. Press the trigger. 2. If the VCM asks for vehicle data, enter the vehicle data, then press store. 3. The VCM asks for module data line 1. Enter the data and press store. 4. The VCM then asks if there is an additional line of data available for that address. Select YES or NO depending on the information in the As Built Data Sheet. 5. Repeat Steps 3 and 4 until the answer is NO for Step 4. 6. The VCM should show a screen stating that the module data was stored. Press the trigger. 7. Follow the on-screen instructions. 8. SELECT: Restore Configuration - New ECU. Press the trigger. 9. The VCM completes loading the retrieved data and displays Module Download Successful. 10. Test the module for correct operation. Using the Vehicle Communication Module (VCM) When the Original Body Chassis Electrical Module is Available 1. With the original module still installed, using the VCM and the latest version of the service function card, SELECT: Programmable Module Installation. 2. Select the module being installed and press the trigger. 3. Follow the on-screen instructions. 4. SELECT: Retrieve Module Configuration - Old ECU. Press the trigger. 5. Follow the on-screen instructions. 6. INSTALL new module, SELECT: Restore Configuration - New ECU. Press the trigger. 7. The VCM completes loading the retrieved data and displays Module Download Successful. 8. Test the module for correct operation. Using the Worldwide Diagnostic System (WDS) When the Original Body Chassis Electrical Module is Not Available 1. Install the new module. 2. Connect the WDS and ID the vehicle as normal. 3. From the Toolbox icon, select and highlight Module Programming. Then highlight the module that was installed and press the check mark. 4. Select and highlight Programmable Module Installation. Then highlight the module that was installed and press the check mark. 5. Follow the on-screen instructions, turn the ignition key to the RUN position and press the check mark. 6. The WDS retrieves the module data, automatically downloads the data into the new module, and displays Module Configuration Complete. 7. If the data is not available in the module, the WDS displays a screen stating to contact the As-Built Data Center. Retrieve the data from Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Page 4300 WWW.FMCDEALER.COM at this time and press the check mark. 8. Enter the module data (the module address and line are displayed to the left of the 3 entry boxes) and press the check mark. 9. The WDS downloads the data into the new module and displays Operation Successful - Programming Complete. 10. Test the module for correct operation. Using the Worldwide Diagnostic System (WDS) When the Original Body Chassis Electrical Module is Available 1. Connect the WDS and ID the vehicle as normal. 2. From the Toolbox icon, select and highlight Module Programming and press the check mark. 3. Select and highlight Programmable Module Installation. 4. Follow the on-screen instructions, turn the ignition key to the OFF position, and press the check mark. 5. Install the new module and press the check mark. 6. Follow the on-screen instructions, turn the ignition key to the ON position, and press the check mark. 7. The module configuration is complete. 8. Test the module for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Page 4301 Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 C109 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 4307 C108 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 4308 Knock Sensor: Description and Operation KNOCK SENSOR (KS) Two Types Of Knock Sensor (KS) The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 4309 Knock Sensor: Service and Repair KNOCK SENSOR (KS) Removal and Installation 1. Remove the intake manifold. 2. Disconnect the knock sensor (KS) electrical connectors. 3. Remove the 2 bolts and the 2 knock sensors. - To install, tighten to 20 Nm (15 lb-ft). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4313 C2160 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4314 Main Relay (Computer/Fuel System): Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4315 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) MIL (applications With A Dedicated Hard Wire MIL Circuit) CHECK ENGINE, SERVICE ENGINE SOON, Or ISO Standard Engine Symbol The MIL notifies the driver that the powertrain control module (PCM) has detected an on board diagnostic (OBD) emission-related component or system concern. When this occurs, an OBD diagnostic trouble code (DTC) sets. - The MIL is located in the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE SOON or the international standards organization (ISO) standard engine symbol. - The MIL is illuminated during the instrument cluster prove out for approximately 4 seconds. - For applications with a dedicated hard wire MIL circuit, the PCM illuminates the MIL until a profile ignition pickup (PIP) signal is detected. The Ranger uses a hard wire circuit. - The MIL remains illuminated after instrument cluster prove out if: an emission-related concern and DTC exists. - no PIP signal is detected (applications with a dedicated hard wire MIL circuit). The PIP signal is generated in the PCM using the crankshaft position (CKP) sensor. For these applications, the MIL can be helpful in diagnosing a no start. - the PCM does not send a control message to the instrument cluster (applications with the MIL controlled through the communication link). - the PCM is operating in the Hardware Limited Operation Strategy (HLOS). - the MIL circuit is shorted to ground (applications with a dedicated hard wire MIL circuit). - The MIL remains off during the instrument cluster prove out if: an indicator or instrument cluster concern is present. - the MIL circuit is open (applications with a dedicated hard wire MIL circuit). - To turn off the MIL after a repair, a reset command from the diagnostic tool must be sent, or 3 consecutive drive cycles must be completed without a concern. - For all MIL concerns, go to Symptom Charts. See: Testing and Inspection/Symptom Related Diagnostic Procedures - If the MIL flashes at a steady rate, a severe misfire condition may exist. - If the MIL flashes erratically, the PCM can reset while cranking if the battery voltage is low. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair ENGINE OIL PRESSURE (EOP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Disconnect the engine oil pressure (EOP) sensor electrical connector. 4. Remove the EOP sensor. - To install, tighten to 21 Nm (15 lb-ft). 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations > Page 4325 C104 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations > Page 4326 Oil Temperature Sensor For ECM: Description and Operation ENGINE OIL TEMPERATURE (EOT) SENSOR Typical Engine Oil Temperature (EOT) Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system. The PCM can use the EOT sensor input to determine the following: - On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM begins reducing power by disabling engine cylinders. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations > Page 4327 Oil Temperature Sensor For ECM: Service and Repair OIL TEMPERATURE SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Drain the engine oil. 4. Disconnect the engine oil temperature (EOT) sensor electrical connector. 5. Remove the EOT sensor. Discard the O-ring seal. - To install, tighten to 21 Nm (15 lb-ft). - Install a new O-ring seal. Lubricate the new O-ring seal with clean engine oil prior to installation. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4332 Oxygen Sensor: Harness Locations View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4333 View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4334 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4335 View 151-8 (Transmission - 6HP26 Automatic Transmission Without Four-Wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4336 View 151-9 (Transmission - 6HP26 Automatic Transmission With Four-Wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4337 View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4338 View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4339 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4340 View 151-8 (Transmission - 6HP26 Automatic Transmission Without Four-Wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4341 View 151-9 (Transmission - 6HP26 Automatic Transmission With Four-Wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 C141 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 4344 C142 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 4345 C171 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 4346 C172 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 4347 Oxygen Sensor: Description and Operation HEATED OXYGEN SENSOR (HO2S) Heated Oxygen Sensor (HO2S) The HO2S detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to a temperature of 800°C (1,472°F). At approximately 300°C (572°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater. The PCM turns the heater on by providing the ground when the correct conditions occur. The heater allows the engine to enter closed loop operation sooner. The use of this heater requires the HO2S heater control to be duty cycled, to prevent damage to the heater. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) HEATED OXYGEN SENSOR (HO2S) Exploded View Special Tool(s) Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the heated oxygen sensor (HO2S) electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 4350 3. Using the special tool, remove the HO2S. - To install, tighten to 46 Nm (34 lb-ft). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 4351 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor CATALYST MONITOR SENSOR Exploded View Special Tool(s) Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the catalyst monitor sensor electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 4352 3. Using the special tool, remove the catalyst monitor sensor. - To install, tighten to 46 Nm (34 lb-ft). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch POWER STEERING PRESSURE (PSP) SWITCH Typical Power Steering Pressure (PSP) Switch The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch > Page 4357 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor POWER STEERING PRESSURE (PSP) SENSOR Typical Power Steering Pressure (PSP) Sensor The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM changes as the hydraulic pressure changes. The PCM uses the input signal from the PSP sensor to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP sensor signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback Exhaust Gas Recirculation (EGR) (DPFE) Sensor Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback Exhaust Gas Recirculation (EGR) (DPFE) Sensor DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) (DPFE) SENSOR DPFE Sensor The DPFE sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through 2 hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the DPFE sensor housing for identification (note that the HI signal uses a larger diameter hose). The DPFE sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the powertrain control module (PCM) as EGR flow rate feedback. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback Exhaust Gas Recirculation (EGR) (DPFE) Sensor > Page 4362 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback Exhaust Gas Recirculation (EGR) (DPFE) Sensor - Tube Mounted DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) (DPFE) SENSOR - TUBE MOUNTED DPFE Sensor - Tube Mounted The tube mounted DPFE sensor is identical in operation as the larger plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations Body Control Module: Locations VEHICLE SECURITY MODULE (VSM) View 151-17 (RH A-Pillar) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 4367 Body Control Module: Diagrams VEHICLE SECURITY MODULE (VSM) C2113a C2113b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 4368 C2113c Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) Body Control Module: Service and Repair Driver Seat Module (DSM) DRIVER SEAT MODULE (DSM) Removal and Installation CAUTION: - Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. - Prior to the removal of the module, it is necessary to upload module configuration information to the appropriate diagnostic equipment. This information needs to be downloaded into the new module once installed. 1. NOTE: The module is accessed with the seat fully in the UP position. Position the driver seat module forward to remove it from the bracket. 2. Disconnect the battery. 3. Disconnect the electrical connectors and remove the DSM. 4. CAUTION: Once the module is installed it is necessary to download the module configuration information from the diagnostic tool into the new module. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 4371 Body Control Module: Service and Repair Vehicle Security Module VEHICLE SECURITY MODULE Removal CAUTION: The steps included in the vehicle security module removal and installation procedure are critical to restoring the vehicle security and tire pressure monitoring systems to normal operation. A new vehicle security module is delivered in manufacturing mode with 6 pre-set diagnostic trouble codes (DTCs) related to the tire pressure monitoring system (TPMS). The presence of these DTCs requires the installation procedures be followed in order to clear the DTCs and enable normal vehicle security module operations. 1. NOTE: Prior to the removal of the vehicle security module, it is necessary to upload the module configuration information to the diagnostic tool. This information must be downloaded to the new vehicle security module after installation. Disconnect the battery. 2. Remove the pin-type retainer and the RH A-pillar lower trim panel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 4372 3. Remove the glove compartment. 4. Disconnect the 3 electrical connectors. 5. Remove the 2 screws and the vehicle security module. Installation 1. Position the vehicle security module and install the 2 screws. - Tighten the screws to 6 Nm (53 lb-in). 2. Connect the 3 electrical connectors. 3. Position the RH A-pillar lower trim panel and install the pin-type retainer. 4. Install the glove compartment 5. Connect the battery. 6. NOTE: When successful, this step provides the calibration necessary for vehicle security module operation and clears DTC B2477. The clearing of the DTC indicates the calibration data has been successfully downloaded to the vehicle security module. Download the vehicle security module configuration information from the diagnostic tool to the vehicle security module. 7. NOTE: When successful, this step clears DTCs B2868, B2869, B2870 and B2871. The clearing of these DTCs indicates the vehicle security module has recognized the tire pressure sensors during the training procedure. Train the tire pressure sensors. 8. Clear the DTCs. 9. NOTE: - DTC C2780 will not clear if any other DTCs are present in the vehicle security module. - This step is required to clear DTC C2780, allow the vehicle security module to exit the manufacturing mode, and to be sure there are no other concerns with the newly programmed vehicle security module. Carry out the vehicle security module on-demand self-test. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation Electronic Throttle Control Module: Description and Operation TORQUE BASED ELECTRONIC THROTTLE CONTROL (ETC) Overview The torque based ETC is a hardware and software strategy that delivers an engine output torque (via throttle angle) based on driver demand (pedal position). It uses an electronic throttle body, the powertrain control module (PCM), and an accelerator pedal assembly to control the throttle opening and engine torque. The ETC system replaces the standard cable operated accelerator pedal, idle air control (IAC) valve, 3-wire throttle position sensor (TPS), and mechanical throttle body. Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque during shifts, and by calculating this desired torque, the system prevents engine lugging (low RPM and low manifold vacuum) while still delivering the performance and torque requested by the driver. It also enables many fuel economy/emission improvement technologies such as variable camshaft timing (VCT) (deliver same torque during transitions). Torque based ETC also results in less intrusive vehicle and engine speed limiting, along with smoother traction control. Other benefits of ETC are: eliminate cruise control actuators - eliminate idle air control (IAC) valve - better airflow range - packaging (no cable) - more responsive powertrain at altitude and improved shift quality It should be noted that the ETC system illuminates a powertrain malfunction indicator (wrench) on the instrument cluster when a concern is present. Concerns are accompanied by diagnostic trouble codes (DTCs) and may also illuminate the malfunction indicator lamp (MIL). Electronic Throttle Body (ETB) The ETB has the following characteristics: 1. The throttle actuator control (TAC) motor is a DC motor controlled by the PCM (requires 2-wires). The gear ratio from the motor to the throttle plate shaft is 17:1. 2. There are 2 designs: parallel and in-series. The parallel design has the motor under the bore parallel to the plate shaft. The motor housing is integrated into the main housing. The in-series design has a separate motor housing. 3. Two springs are used: one is used to close the throttle (main spring) and the other is in a plunger assembly that results in a default angle when no power is applied. This is for limp home reasons (the force of the plunger spring is 2 times stronger than the main spring). The default angle is usually set to result in a top vehicle speed of 48 km/h (30 mph) Typically this throttle angle is 7 to 8 degrees from the hard-stop angle. 4. The closed throttle plate hard stop is used to prevent the throttle from binding in the bore (~0.75 degree). This hard stop setting is not adjustable and is set to result in less airflow than the minimum engine airflow required at idle. 5. Unlike cable operated throttle bodies, the intent for the ETB is not to have a hole in the throttle plate or to use plate sealant. The hole is not required in the ETB because the required idle airflow is provided by the plate angle in the throttle body assembly. This plate angle controls idle, idle quality, and eliminates the need for an IAC valve. 6. The throttle position (TP) sensor has 2 signal circuits in the sensor for redundancy. The redundant throttle position signals are required for increased monitoring reasons. The first TP signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). During normal operation the negative slope TP signal (TP1) is used by the control strategy as the indication of throttle position. The TP sensor assembly requires 4 circuits. 5-volt reference voltage - Signal return (ground) - TP1 voltage with negative voltage slope (5-0 volts) - TP2 voltage with positive voltage slope (0-5 volts) Accelerator Pedal Position (APP) Sensors Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 4376 Electronic Throttle Body (ETB) And Accelerator Pedal Assembly The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1. There are 3 pedal position signals required for system monitoring. APP1 has a negative slope (increasing angle, decreasing voltage) and APP2 and APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. 2. There are 2 VREF circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. 2 reference voltage circuits (5 volts) - 2 signal return (ground) circuits - APP1 voltage with negative voltage slope (5-0 volts) - APP2 voltage with positive voltage slope (0-5 volts) - APP3 voltage with positive voltage slope (0-5 volts) 3. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. 4. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. A value is substituted for an incorrect signal if 2 of the 3 signals are incorrect. Electronic Throttle Control (ETC) System Strategy Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 4377 ETC System The torque based ETC strategy was developed to improve fuel economy and to accommodate variable camshaft timing (VCT). This is possible by not coupling the throttle angle to the driver pedal position. Uncoupling the throttle angle (produce engine torque) from the pedal position (driver demand) allows the powertrain control strategy to optimize fuel control and transmission shift schedules while delivering the requested wheel torque. The ETC monitor system is distributed across 2 processors within the PCM: the main powertrain control processor unit (CPU) and a monitoring processor called an enhanced-quizzer (E-Quizzer) processor. The primary monitoring function is carried out by the independent plausibility check (IPC) software, which resides on the main processor. It is responsible for determining the driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the generated torque exceeds driver demand by a specified amount, the IPC takes appropriate corrective action. ETC System Failure Mode And Effects Management (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 4378 ETC System Failure Mode And Effects Management (Part 2) Since the IPC and the main controller share the same processor, they are subject to a number of potential common failure modes. Therefore, the E-Quizzer processor was added to redundantly monitor selected PCM inputs and to act as an intelligent watchdog and monitor the performance of the IPC and the main processor. If it determines that the IPC function is impaired in any way, it takes appropriate failure mode and effects management (FMEM) actions. Electronic Throttle Monitor Operation: Electronic Throttle Monitor Operation (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 4379 Electronic Throttle Monitor Operation (Part 2) Accelerator and Throttle Position (TP) Sensor Inputs Accelerator Pedal Position (APP) Sensor Check: Accelerator Pedal Position (APP) Sensor Check Throttle Position (TP) Sensor Check: Throttle Position (TP) Sensor Check Throttle Plate Position Controller (TPPC) Outputs Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 4380 Throttle Plate Controller Check Operation The purpose of the TPPC is to maintain the throttle position at the desired throttle angle. It is a separate chip embedded in the PCM. The desired angle is communicated from the main CPU via a 312.5 Hz duty cycle (DC) signal. The TPPC interprets the duty cycle signal as follows: Less than 5% - Out of range, limp home default position. - Greater than or equal to 5% but less than 6% - Commanded default position, closed. - Greater than or equal to 6% but less than 7% - Commanded default position. Used for key-on, engine off. - Greater than or equal to 7% but less than 10% - Closed against hard-stop. Used to learn zero throttle angle position (hard-stop) after key-up. - Greater than or equal to 10% but less than or equal to 92% - Normal operation, between 0 degrees (hard-stop) and 82 degrees, 10% duty cycle equals 0 degrees throttle angle, 92% duty cycle equals 82 degrees throttle angle. - Greater than 92% but less than or equal to 96% - Wide Open Throttle, 82 to 86 degrees throttle angle. - Greater than 96% but less than or equal to 100% - Out of Range, limp home default position. The desired angle is relative to the hard-stop angle. The hard-stop angle is learned during each key-up process before the main CPU requests the throttle plate be closed against the hard-stop. The output of the TPPC is a voltage request to the H-driver (also in PCM). The H driver is capable of positive or negative voltage to the electronic throttle body motor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations View 151-1 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 4386 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 4387 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 4388 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 4389 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 4390 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 4391 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 4392 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 4393 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 4394 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 4395 Engine Control Module: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 4396 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 4397 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 4398 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 4399 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 4400 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 4401 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 4402 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 4403 Engine Control Module: Connector Views C175b (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 4404 C175b (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 4405 C175e (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 4406 C175e (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 4407 C175t (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 4408 C175t (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Flash Electrically Erasable Programmable Read Only Memory (EEPROM) Engine Control Module: Service and Repair Flash Electrically Erasable Programmable Read Only Memory (EEPROM) FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) Description The flash electrically erasable programmable read only memory (EEPROM) is contained in an integrated circuit (IC) internal to the powertrain control module (PCM). The EEPROM contains the vehicle strategy including calibration information specific to the vehicle, and is capable of being programmed or flashed repeatedly. As part of the calibration there is an area referred to as the vehicle identification (VID) block. The VID block is programmed when installing a new PCM as described under Programming the VID Block for a Replacement PCM. Failure to carry out this procedure may generate fault code P1635 or P1639. The VID block in an existing PCM can also be tailored to accommodate various hardware or parameter changes made to the vehicle since production. Failure to carry out this procedure properly may generate fault code P1635, Tire/Axle Ratio out of Acceptable Range. An incorrect tire/axle ratio is one of the main causes for fault code P1639. This is described under Making Changes to the VID Block and also under Making Changes to the PCM Calibration. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the vehicle identification number (VIN), octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control, and 4-wheel drive electronic shift-on-the-fly (ESOF) versus manual shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported by the VID block is displayed on the diagnostic tool. When changing items in the VID block, the strategy places range limits on certain items such as tire and axle ratio. The number of times the VID block may be reconfigured is limited. When this limit is reached, the diagnostic tool displays a message indicating the need to flash the PCM again to reset the VID block. Programming can be carried out by a local Ford dealer or any non-Ford facility. Refer to the diagnostic tool manufacturer's instruction manual for details. Programming the VID Block for a Replacement PCM A new PCM contains the latest strategy and calibration level for a particular vehicle. However, the VID block is blank and will need programming. There are 2 procedures available. The first is an automatic data transfer from the old PCM to the new PCM, and the second is manual data entry into the new PCM. Automatic data transfer is carried out if the old PCM is capable of communicating. This is done by the use of a diagnostic tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can then be downloaded to the new PCM after it has been installed. Manual data entry must be carried out if the old module is damaged or incapable of communicating. Remove and install a new PCM. Using a compatible diagnostic tool, select and carry out the module/parameter programming, referring to the diagnostic tool manufacturer's instruction manual. Make certain that all parameters are included. Failure to properly program tire size in revolutions per mile, (rev/mile equals 63,360 divided by the tire circumference in inches), axle ratio, 4x4/4x2, and/or MSOF/ESOF may result in codes P1635 and P1639. You may be instructed to contact the As-Built Data Center for the information needed to manually update the VID block with the diagnostic tool. Contact the center only if the old PCM cannot be used or the data is corrupt. For Ford and L-M technicians, contact your National Hotline or the Professional Technician Society (PTS) website for As-Built data listed under the Service Publications Index. Non-Ford technicians use the Motorcraft(R) website at www.motorcraft.com. From the Motorcraft(R) homepage, use the search function to find the Module Programming or As-Built Data. For Ford and L-M technicians, check the Programmable Module Installation link on the PTS website for quick Programmable Module data information by vehicle when using the worldwide diagnostic system (WDS) or New Generation STAR (NGS). Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate the vehicle hardware. Refer to PCM/Module Reprogramming on the diagnostic tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM needs to be completely reprogrammed. This is due to changes made to the strategy or calibration after production, or the need to reset the VID block because it has reached its limit. Refer to PCM/Module Reprogramming on the diagnostic tool. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Flash Electrically Erasable Programmable Read Only Memory (EEPROM) > Page 4411 Engine Control Module: Service and Repair Removal and Installation POWERTRAIN CONTROL MODULE (PCM) Special Tool(s) Special Tool(s) Removal and Installation 1. NOTE: Refer to Computers and Control Systems for correct worldwide diagnostic system (WDS) hook-up procedure. If servicing the powertrain control module (PCM), connect the diagnostic tool to the vehicle. Allow the diagnostic tool to identify the vehicle and obtain configuration data. All programmable module information will automatically be retrieved by the WDS. 2. Disconnect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Flash Electrically Erasable Programmable Read Only Memory (EEPROM) > Page 4412 3. Disconnect the PCM electrical connectors. 4. Remove the 4 bolts and the PCM. - To install, tighten to 7 Nm (62 lb-in). 5. If servicing the PCM bracket, remove the 3 bolts and the PCM bracket. - To install, tighten to 10 Nm (89 lb-in). 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 4416 C2160 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 4417 Main Relay (Computer/Fuel System): Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 4418 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4423 C2040 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4424 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The APP sensor is an input to the powertrain control module (PCM) and is used to determine the torque demand. There are 3 pedal position signals in the sensor. Signal 1, APPS1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, APPS2 and APPS3, both have a positive slope (increasing angle, increasing voltage). During normal operation APPS1 is used as the indication of pedal position by the strategy. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. There are 2 reference voltage circuits and 2 signal return circuits for the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4428 C1454 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4429 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW (MAF) SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT Sensor Wire Where Applicable) Terminals Typical Mass Air Flow (MAF) Sensor Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4430 Typical Drop-in Mass Air Flow (MAF) Sensor The MAF sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above the ambient temperature as measured by a constant cold wire. If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the mass air flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. Most MAF sensors have integrated bypass technology (IBT) with an integrated intake air temperature (IAT) sensor. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4431 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the mass air flow (MAF) sensor electrical connector. 3. Remove the 2 bolts and the MAF sensor. - To install, tighten to 7 Nm (62 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1 C1366 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1 > Page 4437 C1367 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 4438 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR Typical Synchronizer Hall-Effect CMP Sensor Typical Variable Reluctance CMP Sensor The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston No. 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to select the correct ignition coil to fire. Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor and the 2-pin connector variable reluctance type sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 4439 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the camshaft position (CMP) sensor electrical connector. 3. Remove the bolt and the CMP sensor. Discard the O-ring seal. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Description and Operation Clutch Switch: Description and Operation CLUTCH PEDAL POSITION (CPP) SWITCH Typical Clutch Pedal Position (CPP) Switch The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine load. The PCM uses the load information for mass air flow and fuel calculations. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4446 C101 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4447 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Typical Crankshaft Position (CKP) Sensor The CKP sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L 10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4448 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the accessory drive belt. 4. Disconnect the A/C compressor electrical connector. 5. Remove the 3 bolts and position the A/C compressor aside. - To install, tighten to 25 Nm (18 lb-ft). 6. Disconnect the crankshaft position (CKP) sensor electrical connector. 7. Remove the bolt and the CKP sensor. Discard the O-ring seal. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the new O-ring seal with clean engine oil prior to installation. 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 4452 C107 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > CHT Sensor Engine Temperature Sensor: Description and Operation CHT Sensor The CHT sensor: ^ is mounted into the wall of the cylinder head and is not connected to any coolant passages. ^ sends the PCM a signal indicating cylinder head temperature. ^ if the temperature exceeds approximately 121 °C (250°F), the PCM disables half of the fuel injectors at a time. The PCM will alternate which fuel injectors are disabled every 32 engine cycles. The cylinders that are not being fuel injected act as air pumps to aid in engine cooling. ^ if the temperature exceeds approximately 166°C (330°F), the PCM disables all of the fuel injectors until the engine temperature drops below approximately 1 54°C (31 0°F). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > CHT Sensor > Page 4455 Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical Cylinder Head Temperature (CHT) Sensor The CHT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. The CHT sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM initiates a fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern such as low coolant or coolant loss could cause an overheating condition. As a result damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > Page 4456 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR Removal and Installation 1. Remove the intake manifold. 2. Disconnect the cylinder head temperature (CHT) sensor jumper harness electrical connector. 3. Remove and discard the CHT sensor. - To install, tighten to 10 Nm (89 lb-in). - Coat the CHT sensor threads with high temperature nickel anti-seize lubricant prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation FUEL LEVEL INPUT (FLI) NOTE: The Ford GT uses a piezoelectric sonar type fuel level sensor. The sensor is located in the tank and the sensor signal is provided as a communications network message by the instrument cluster to the PCM. The FLI is either a hard wire signal input to the PCM from the fuel pump (FP) module or a communications network message. Most vehicle applications use a potentiometer type FLI sensor connected to a float in the FP module to determine fuel level. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 4460 Fuel Level Sensor: Service and Repair FUEL PUMP MODULE Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 4461 Part 2 Exploded View Special Tool(s) Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 4462 Removal and Installation WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. 1. Remove the fuel tank. 2. Disconnect the fuel and vapor tubes from the fuel pump module. 3. Using the special tool, remove the fuel pump lock ring. 4. CAUTION: Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Page 4463 - Note the location of the fuel pump alignment tabs. - Carefully remove the fuel pump assembly to avoid damaging the fuel level sensor. Remove the fuel pump module assembly. Remove and discard the O-ring seal. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE (FTP) SENSOR Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The FTP sensor or in-line FTP sensor is used to measure the fuel tank pressure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Page 4467 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR Removal and Installation 1. Remove the fuel tank. 2. Disconnect the fuel vapor tube quick connect couplings from the fuel vapor/grade vent valves. 3. Disconnect the fuel vapor tube quick connect couplings from the fuel pump module. 4. Remove the fuel pressure sensor tube assembly. 5. To install, reverse the removal procedure. - Leak test the system. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Evaporative Emission System Leak Test - Carry out the evaporative emission repair verification drive cycle. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Evaporative Emission Repair Verification Drive Cycle Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 4471 C1454 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 4472 Intake Air Temperature Sensor: Description and Operation INTAKE AIR TEMPERATURE (IAT) SENSOR Typical Stand-Alone/Non-Integrated Intake Air Temperature (IAT) Sensors Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into A Drop-in Or Flange-type MAF Sensor The IAT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 4473 fuel, spark, and air flow. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Currently there are 2 design types of IAT sensors used, a stand-alone/non-integrated type and a integrated type. Both types function the same, however the integrated type is incorporated into the mass air flow (MAF) sensor instead of being a stand alone sensor. Supercharged vehicles use 2 IAT sensors. Both sensors are thermistor type devices and operate as described. However, one is located before the supercharger at the air cleaner for standard OBD/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 C109 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 4479 C108 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 4480 Knock Sensor: Description and Operation KNOCK SENSOR (KS) Two Types Of Knock Sensor (KS) The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 4481 Knock Sensor: Service and Repair KNOCK SENSOR (KS) Removal and Installation 1. Remove the intake manifold. 2. Disconnect the knock sensor (KS) electrical connectors. 3. Remove the 2 bolts and the 2 knock sensors. - To install, tighten to 20 Nm (15 lb-ft). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair ENGINE OIL PRESSURE (EOP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Disconnect the engine oil pressure (EOP) sensor electrical connector. 4. Remove the EOP sensor. - To install, tighten to 21 Nm (15 lb-ft). 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations > Page 4488 C104 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations > Page 4489 Oil Temperature Sensor For ECM: Description and Operation ENGINE OIL TEMPERATURE (EOT) SENSOR Typical Engine Oil Temperature (EOT) Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system. The PCM can use the EOT sensor input to determine the following: - On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM begins reducing power by disabling engine cylinders. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations > Page 4490 Oil Temperature Sensor For ECM: Service and Repair OIL TEMPERATURE SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Drain the engine oil. 4. Disconnect the engine oil temperature (EOT) sensor electrical connector. 5. Remove the EOT sensor. Discard the O-ring seal. - To install, tighten to 21 Nm (15 lb-ft). - Install a new O-ring seal. Lubricate the new O-ring seal with clean engine oil prior to installation. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4495 Oxygen Sensor: Harness Locations View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4496 View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4497 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4498 View 151-8 (Transmission - 6HP26 Automatic Transmission Without Four-Wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4499 View 151-9 (Transmission - 6HP26 Automatic Transmission With Four-Wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4500 View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4501 View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4502 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4503 View 151-8 (Transmission - 6HP26 Automatic Transmission Without Four-Wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4504 View 151-9 (Transmission - 6HP26 Automatic Transmission With Four-Wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 C141 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 4507 C142 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 4508 C171 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 4509 C172 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 4510 Oxygen Sensor: Description and Operation HEATED OXYGEN SENSOR (HO2S) Heated Oxygen Sensor (HO2S) The HO2S detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to a temperature of 800°C (1,472°F). At approximately 300°C (572°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater. The PCM turns the heater on by providing the ground when the correct conditions occur. The heater allows the engine to enter closed loop operation sooner. The use of this heater requires the HO2S heater control to be duty cycled, to prevent damage to the heater. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) HEATED OXYGEN SENSOR (HO2S) Exploded View Special Tool(s) Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the heated oxygen sensor (HO2S) electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 4513 3. Using the special tool, remove the HO2S. - To install, tighten to 46 Nm (34 lb-ft). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 4514 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor CATALYST MONITOR SENSOR Exploded View Special Tool(s) Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the catalyst monitor sensor electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 4515 3. Using the special tool, remove the catalyst monitor sensor. - To install, tighten to 46 Nm (34 lb-ft). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch POWER STEERING PRESSURE (PSP) SWITCH Typical Power Steering Pressure (PSP) Switch The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch > Page 4520 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor POWER STEERING PRESSURE (PSP) SENSOR Typical Power Steering Pressure (PSP) Sensor The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM changes as the hydraulic pressure changes. The PCM uses the input signal from the PSP sensor to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP sensor signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback Exhaust Gas Recirculation (EGR) (DPFE) Sensor Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback Exhaust Gas Recirculation (EGR) (DPFE) Sensor DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) (DPFE) SENSOR DPFE Sensor The DPFE sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through 2 hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the DPFE sensor housing for identification (note that the HI signal uses a larger diameter hose). The DPFE sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the powertrain control module (PCM) as EGR flow rate feedback. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback Exhaust Gas Recirculation (EGR) (DPFE) Sensor > Page 4525 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback Exhaust Gas Recirculation (EGR) (DPFE) Sensor - Tube Mounted DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) (DPFE) SENSOR - TUBE MOUNTED DPFE Sensor - Tube Mounted The tube mounted DPFE sensor is identical in operation as the larger plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 4529 C189 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Electronic Throttle Body (ETB) Position Sensor Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR The ETB position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB position signals are required for increased monitoring. The first ETB position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). During normal operation the negative slope ETB position sensor signal (TP1) is used by the control strategy as the indication of throttle position. The 2 ETB position sensor signals make sure the PCM receives a correct input even if 1 signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Electronic Throttle Body (ETB) Position Sensor > Page 4532 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor THROTTLE POSITION (TP) SENSOR Typical TP Sensor The TP sensor is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a 3-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page 4533 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Removal 1. Disconnect the battery ground cable. 2. Remove the air cleaner inlet pipe and the air cleaner assembly. 3. Disconnect the throttle position (TP) sensor electrical connector. 4. CAUTION: Failure to remove the TP sensor screws in the following manner will result in damage to the screws. First loosen the screws 1-2 full turns using a hand tool and then use a suitable high speed driver to complete the removal. Remove and discard the 2 screws and the TP sensor. Installation 1. CAUTION: - Do not reuse the TP sensor and screws. A new TP sensor and screws must be installed. - Do not use a high speed driver to install the new screws or damage to the TP sensor can occur. NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor is aligned with the radial locator hole on the throttle body. Position the new TP sensor and install the 2 new screws. Tighten to 3 Nm (27 lb-in). 2. Connect the TP sensor electrical connector. 3. Install the air cleaner and air cleaner inlet pipe. 4. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4537 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4540 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4541 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4542 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4543 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4544 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4545 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4546 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4547 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4548 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4549 Transmission Position Switch/Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4550 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4551 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4552 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4553 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4554 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4555 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4556 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4557 C167 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4558 Transmission Position Switch/Sensor: Adjustments 4R70E/4R75E Transmission Range (TR) Sensor Adjustment Special Tools 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual lever shift control cable. 3. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control lever nut. 2 Remove the manual control lever. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4559 4. Loosen the digital transmission range (TR) sensor bolts. 5. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 6. CAUTION: Tightening one bolt before tightening the other may cause the sensor to bind or become damaged. Using the special tool, align the digital TR sensor and tighten the bolts in an alternating sequence. ^ Tighten to 9 Nm (80 inch lbs.). 7. Install the manual control lever. ^ Position the manual control lever. 2 Install a new manual lever shaft outer nut. ^ Tighten to 33 Nm (24 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4560 8. With the manual lever in overdrive connect the shift lever control cable. 9. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4561 Transmission Position Switch/Sensor: Service and Repair 4R70E/4R75E Automatic Transmission Digital Transmission Range (TR) Sensor Special Tools Removal NOTE: Manual shift lever must be in the NEUTRAL position. 1. With the vehicle in NEUTRAL, position it on a hoist. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4562 2. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual control lever shift control cable. 3. Disconnect the digital TR electrical connector. 4. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control nut. 2 Remove the manual control lever. 5. Remove the digital TR sensor bolts and the digital TR sensor. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4563 1. Install the digital TR sensor and loosely install the bolts. 2. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 3. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. Tighten the digital TR sensor bolts. ^ Tighten to 9 Nm (80 inch lbs.). 4. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual control lever nut. ^ Tighten to 33 Nm (24 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4564 5. Connect the digital TR sensor electrical connector. 6. Connect the shift cable end to the manual lever with the lever in the (D) position. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Output Shaft Speed (OSS) Sensor Vehicle Speed Sensor: Description and Operation Output Shaft Speed (OSS) Sensor OUTPUT SHAFT SPEED (OSS) SENSOR The OSS sensor provides the PCM with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Output Shaft Speed (OSS) Sensor > Page 4569 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) VEHICLE SPEED SENSOR (VSS) Typical Vehicle Speed Sensor (VSS) The VSS is a variable reluctance or HALL-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling, and torque converter clutch scheduling. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 4573 C189 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Electronic Throttle Body (ETB) Position Sensor Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR The ETB position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB position signals are required for increased monitoring. The first ETB position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). During normal operation the negative slope ETB position sensor signal (TP1) is used by the control strategy as the indication of throttle position. The 2 ETB position sensor signals make sure the PCM receives a correct input even if 1 signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Electronic Throttle Body (ETB) Position Sensor > Page 4576 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor THROTTLE POSITION (TP) SENSOR Typical TP Sensor The TP sensor is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a 3-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page 4577 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Removal 1. Disconnect the battery ground cable. 2. Remove the air cleaner inlet pipe and the air cleaner assembly. 3. Disconnect the throttle position (TP) sensor electrical connector. 4. CAUTION: Failure to remove the TP sensor screws in the following manner will result in damage to the screws. First loosen the screws 1-2 full turns using a hand tool and then use a suitable high speed driver to complete the removal. Remove and discard the 2 screws and the TP sensor. Installation 1. CAUTION: - Do not reuse the TP sensor and screws. A new TP sensor and screws must be installed. - Do not use a high speed driver to install the new screws or damage to the TP sensor can occur. NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor is aligned with the radial locator hole on the throttle body. Position the new TP sensor and install the 2 new screws. Tighten to 3 Nm (27 lb-in). 2. Connect the TP sensor electrical connector. 3. Install the air cleaner and air cleaner inlet pipe. 4. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4581 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4584 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4585 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4586 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4587 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4588 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4589 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4590 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4591 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4592 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4593 Transmission Position Switch/Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4594 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4595 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4596 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4597 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4598 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4599 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4600 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4601 C167 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4602 Transmission Position Switch/Sensor: Adjustments 4R70E/4R75E Transmission Range (TR) Sensor Adjustment Special Tools 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual lever shift control cable. 3. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control lever nut. 2 Remove the manual control lever. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4603 4. Loosen the digital transmission range (TR) sensor bolts. 5. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 6. CAUTION: Tightening one bolt before tightening the other may cause the sensor to bind or become damaged. Using the special tool, align the digital TR sensor and tighten the bolts in an alternating sequence. ^ Tighten to 9 Nm (80 inch lbs.). 7. Install the manual control lever. ^ Position the manual control lever. 2 Install a new manual lever shaft outer nut. ^ Tighten to 33 Nm (24 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4604 8. With the manual lever in overdrive connect the shift lever control cable. 9. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4605 Transmission Position Switch/Sensor: Service and Repair 4R70E/4R75E Automatic Transmission Digital Transmission Range (TR) Sensor Special Tools Removal NOTE: Manual shift lever must be in the NEUTRAL position. 1. With the vehicle in NEUTRAL, position it on a hoist. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4606 2. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual control lever shift control cable. 3. Disconnect the digital TR electrical connector. 4. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control nut. 2 Remove the manual control lever. 5. Remove the digital TR sensor bolts and the digital TR sensor. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4607 1. Install the digital TR sensor and loosely install the bolts. 2. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 3. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. Tighten the digital TR sensor bolts. ^ Tighten to 9 Nm (80 inch lbs.). 4. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual control lever nut. ^ Tighten to 33 Nm (24 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4608 5. Connect the digital TR sensor electrical connector. 6. Connect the shift cable end to the manual lever with the lever in the (D) position. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 C1451 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 > Page 4613 C1452 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Page 4614 Variable Valve Timing Actuator: Description and Operation VARIABLE CAMSHAFT TIMING (VCT) SYSTEM Overview The VCT enables rotation of the camshaft(s) relative to the crankshaft rotation as a function of engine operating conditions. There are 4 types of VCT systems. Exhaust phase shifting (EPS) system - the exhaust cam is the active cam being retarded. - Intake phase shifting (IPS) system - the intake cam is the active cam being advanced. - Dual equal phase shifting (DEPS) system - both intake and exhaust cams are phase shifted and equally advanced or retarded. - Dual independent phase shifting (DIPS) system - where both the intake and exhaust cams are shifted independently. All systems have 4 operational modes: idle, part throttle, wide open throttle (WOT), and default mode. At idle and low engine speeds with closed throttle, the powertrain control module (PCM) determines the phase angle based on air flow, engine oil temperature and engine coolant temperature. At part and wide open throttle the PCM determines the phase angle based on engine RPM, load, and throttle position. VCT systems provide reduced emissions and enhanced engine power, fuel economy and idle quality. IPS Systems also have the added benefit of improved torque. In addition, some VCT system applications can eliminate the need for an external exhaust gas recirculation (EGR) system. The elimination of the EGR system is accomplished by controlling the overlap time between the intake valve opening and exhaust valve closing. Currently, both the IPS and DEPS systems are used Variable Camshaft Timing (VCT) System Variable Camshaft Timing System The VCT system consists of an electric hydraulic positioning control solenoid, a camshaft position (CMP) sensor, and a trigger wheel. The CMP trigger wheel has a number of equally spaced teeth equal to the number (n) of cylinders on a bank plus one extra tooth (n+1). Four cylinder and V8 engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1 tooth trigger wheel. The extra tooth placed between the equally spaced teeth represents the CMP signal for that bank. A crankshaft position sensor (CKP) provides the PCM with crankshaft positioning information in 10 degree increments. 1. The PCM receives input signals from the intake air temperature (IAT) sensor, engine coolant temperature (ECT) sensor, engine oil temperature (EOT) sensor, CMP, throttle position (TP) sensor, mass air flow (MAF) sensor, and CKP to determine the operating conditions of the engine. At idle and low engine speeds with closed throttle, the PCM controls the camshaft position based on ECT, EOT, IAT, and MAF. During part and wide open throttle, the camshaft position is determined by engine RPM, load and throttle position. The VCT system does not operate until the engine is at normal operating temperature. 2. The VCT system is enabled by the PCM when the correct conditions are met. 3. The CKP signal is used as a reference for CMP positioning. 4. The VCT solenoid valve is an integral part of the VCT system. The solenoid valve controls the flow of engine oil in the VCT actuator assembly. As the PCM controls the duty cycle of the solenoid valve, oil pressure/flow advances or retards the cam timing. Duty cycles near 0% or 100% represent rapid movement of the camshaft. Retaining a fixed camshaft position is accomplished by dithering (oscillating) the solenoid valve duty cycle. The PCM calculates and determines the desired camshaft position. It continually updates the VCT solenoid duty cycle until the desired position is Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Page 4615 achieved. A difference between the desired and actual camshaft position represents a position error in the PCM VCT control loop. The PCM disables the VCT and places the camshaft in a default position if a concern is detected. A related DTC is also set when the concern is detected. 5. When the VCT solenoid is energized, engine oil is allowed to flow to the VCT actuator assembly which advances or retards the camshaft timing. One half of the VCT actuator is coupled to the camshaft and the other half is connected to the timing chain. Oil chambers between the 2 halves couple the camshaft to the timing chain. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the camshaft to rotate in either an advance or retard position depending on the oil flow. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Service and Repair Variable Valve Timing Solenoid: Service and Repair VARIABLE CAMSHAFT TIMING OIL CONTROL SOLENOID LH Shown, RH Similar. Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the variable camshaft timing (VCT) oil control solenoid electrical connector. 3. Remove the VCT oil control solenoid grommet. 4. Remove the bolt and the VCT oil control solenoid. Discard the O-ring seal. - To install, tighten to 5 Nm (44 lb-in). - Install a new O-ring seal. Lubricate the new O-ring seal with clean engine oil prior to installation. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Output Shaft Speed (OSS) Sensor Vehicle Speed Sensor: Description and Operation Output Shaft Speed (OSS) Sensor OUTPUT SHAFT SPEED (OSS) SENSOR The OSS sensor provides the PCM with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Output Shaft Speed (OSS) Sensor > Page 4623 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) VEHICLE SPEED SENSOR (VSS) Typical Vehicle Speed Sensor (VSS) The VSS is a variable reluctance or HALL-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling, and torque converter clutch scheduling. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Solenoid > Component Information > Description and Operation Air Diverter Solenoid: Description and Operation SECONDARY AIR INJECTION (AIR) BYPASS SOLENOID Secondary AIR Bypass Solenoid The secondary AIR bypass solenoid is used by the PCM to control vacuum to the secondary air injection diverter (AIR diverter) valve. The secondary AIR bypass solenoid is a normally closed solenoid. The secondary AIR bypass solenoid also has a filtered vent feature to permit vacuum release. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve > Component Information > Description and Operation Air Diverter Valve: Description and Operation SECONDARY AIR DIVERTER VALVE Secondary AIR Diverter Valve The secondary AIR diverter valve is used with the secondary AIR pump to provide on/off control of air to the exhaust manifold and catalytic converter. When the secondary AIR pump is on and vacuum is supplied to the AIR diverter valve, air passes the integral check valve disk. When the secondary AIR pump is off, and vacuum is removed from the AIR diverter valve, the integral check valve disk is held on the seat and stops air from being drawn into the exhaust system and prevents the back flow of the exhaust into the secondary AIR system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump > Component Information > Description and Operation Air Injection Pump: Description and Operation SECONDARY AIR PUMP Secondary Air Pump The secondary AIR pump provides pressurized air to the secondary AIR system. The secondary AIR pump functions independently of RPM and is controlled by the PCM. The secondary AIR pump is only used for short periods of time. Delivery of air is dependent on the amount of system backpressure and system voltage. The secondary AIR pump draws dry filtered air from the Intake Air System down stream of the MAF/IAT sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation Catalytic Converter: Description and Operation CATALYST AND EXHAUST SYSTEMS Overview V-Engines In-Line Engines The catalytic converter and exhaust Systems work together to control the release of harmful engine exhaust emissions into the atmosphere. The engine exhaust gas consists mainly of nitrogen (N), carbon dioxide (CO2) and water vapor (H2O). However, it also contains carbon monoxide (CO), oxides of nitrogen (NOx), hydrogen (H), and various unburned hydrocarbons (HCs). The major air pollutants of CO, NOx, and HCs, and their emission into the atmosphere must be controlled. The exhaust system generally consists of an exhaust manifold, front exhaust pipe, front heated oxygen sensor (HO2S), rear exhaust pipe, catalyst HO2S, a muffler, and an exhaust tailpipe. The catalytic converter is typically installed between the front and rear exhaust pipes. On some vehicle applications, more than one catalyst is used between the front and rear exhaust pipes. Catalytic converter efficiency is monitored by the on-board diagnostic (OBD) system strategy in the PCM. For information on the OBD catalyst monitor, refer to the description for the Catalyst Efficiency Monitor. The number of HO2Ss used in the exhaust stream and the location of these sensors depend on the vehicle emission certification level (LEV, LEV-II, ULEV, PZEV). On most vehicles only 2 HO2Ss are used in an exhaust stream. The front sensors (HO2S11/HO2S21) before the catalyst are used for primary fuel control while the ones after the catalyst (HO2S12/HO2S22) are used to monitor catalyst efficiency. However, some partial zero emission vehicles (PZEV) use 3 HO2Ss for each engine bank. The stream 1 sensors (HO2S11/HO2S21) located before the catalyst are used for primary fuel control, the stream 2 sensors (HO2S12/HO2S22) are used to monitor the light-off catalyst, and the stream 3 sensors (HO2S13/HO2S23) located after the catalyst are used for long term fuel trim control to optimize catalyst efficiency (fore aft oxygen sensor control). Current PZEV vehicles use only a Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 4638 4-cylinder engine, so only the bank 1 HO2Ss are used. Catalytic Converter A catalyst is a material that remains unchanged when it initiates and increases the speed of a chemical reaction. A catalyst also enables a chemical reaction to occur at a lower temperature. The concentration of exhaust gas products released to the atmosphere must be controlled. The catalytic converter assists in this task. It contains a catalyst in the form of a specially treated ceramic honeycomb structure saturated with catalytically active precious metals. As the exhaust gases come in contact with the catalyst, they are changed into mostly harmless products. The catalyst initiates and speeds up heat producing chemical reactions of the exhaust gas components so they are used up as much as possible. Light Off Catalyst As the catalyst heats up, converter efficiency rises rapidly. The point at which conversion efficiency exceeds 50% is called catalyst light off. For most catalysts this point occurs at 246°C to 302°C (475°F to 575°F). A fast light catalyst is a 3-way catalyst (TWC) that is located as close to the exhaust manifold as possible. Because the light off catalyst is located close to the exhaust manifold it lights off faster and reduce emissions quicker than the catalyst located under the body. Once the catalyst lights off, the catalyst quickly reaches the maximum conversion efficiency for that catalyst. Three-Way Catalyst (TWC) Conversion Efficiency TWC Conversion Efficiency Chart A TWC requires a stoichiometric fuel ratio, 14.7 pounds of air to 1 pound of fuel (14.7:1), for high conversion efficiency. In order to achieve these high efficiencies, the air/fuel ratio must be tightly controlled with a narrow window of stoichiometry. Deviations outside of this window greatly decrease the conversion efficiency. For example a rich mixture decreases the HC and CO conversion efficiency while a lean mixture decreases the NOx conversion efficiency. Exhaust System Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 4639 Typical Bank 1 Catalyst 2 HO2S Configuration Typical Bank 1 Catalyst 3 HO2S Configuration The purpose of the exhaust system is to convey engine emissions from the exhaust manifold to the atmosphere. Engine exhaust emissions are directed from the engine exhaust manifold to the catalytic converter through the front exhaust pipe. A HO2S is mounted on the front exhaust pipe before the catalyst. The catalytic converter reduces the concentration of CO, unburned HCs, and NOx in the exhaust emissions to an acceptable level. The reduced exhaust emissions are directed from the catalytic converter past another HO2S mounted in the rear exhaust pipe and then on into the muffler. Finally, the exhaust emissions are directed to the atmosphere through an exhaust tailpipe. On some PZEV, there is a total of 3 HO2S in the exhaust stream. One near the exhaust manifold (stream 1), one in the middle of the light-off catalyst (stream 2), and the third (stream 3) is mounted after the light-off catalyst. Underbody Catalyst The underbody catalyst is located after the light off catalyst. The underbody catalyst may be in-line with the light off catalyst, or the underbody catalyst may be common to 2 light off catalysts, forming a Y pipe configuration. For an exact configuration of the catalyst and exhaust system for a specific vehicle, refer to Catalytic Converter, Exhaust System. Three-Way Catalytic (TWC) Converter The TWC converter contains either platinum (Pt) and rhodium (Rh) or palladium (Pd) and rhodium (Rh). The TWC converter catalyzes the oxidation Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 4640 reactions of unburned HCs and CO and the reduction reaction of NOx. The 3-way conversion can be best accomplished by always operating the engine air fuel/ratio at or close to stoichiometry. Exhaust Manifold Runners The exhaust manifold runners collect exhaust gases from engine cylinders. The number of exhaust manifolds and exhaust manifold runners depends on the engine configuration and number of cylinders. Exhaust Pipes Exhaust pipes are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The pipes serve as guides for the flow of exhaust gases from the engine exhaust manifold through the catalytic converter and the muffler. Heated Oxygen Sensors (HO2S) The HO2S provide the powertrain control module (PCM) with voltage and frequency information related to the oxygen content of the exhaust gas. Muffler Mufflers are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The muffler reduces the level of noise produced by the engine, and also reduces the noise produced by exhaust gases as they travel from the catalytic converter to the atmosphere. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams C1195 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Page 4645 Canister Purge Control Valve: Description and Operation EVAPORATIVE EMISSION (EVAP) CANISTER PURGE VALVE EVAP Canister Purge Valve Electronic EVAP Canister Purge Valve NOTE: The EVAP canister purge valve may also be referred to as a vapor management valve (VMV). The EVAP canister purge valve is part of the enhanced EVAP system that is controlled by the PCM. This valve controls the flow of vapors (purging) from the EVAP canister to the intake manifold during various engine operating modes. The EVAP canister purge valve is a normally closed valve. The electronic EVAP canister purge valve controls the flow of vapors electronically by way of a solenoid thereby, eliminating the need for an electronic vacuum regulator and vacuum diaphragm. The PCM outputs a signal between 0% and 100% duty cycle to control the EVAP canister purge valve. On applications with an electronic EVAP canister purge valve, the PCM outputs a signal between 0 mA and 1,000 mA to control the solenoid. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Page 4646 Canister Purge Control Valve: Service and Repair EVAPORATIVE EMISSION CANISTER PURGE VALVE Removal and Installation WARNING: - The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery ground cable from the battery to minimize the possibility of an electrical spark occurring, possibly causing a fire or explosion if fuel vapor or liquid fuel are present in the area. Failure to follow these instructions can result in personal injury. - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury. 1. Disconnect the battery ground cable. 2. Disconnect the evaporative emissions (EVAP) canister purge solenoid electrical connector. 3. Disconnect the 2 fuel vapor tubes quick connect couplings. 4. Remove the EVAP canister purge solenoid from the bracket. 5. To install, reverse the removal procedure. - Leak Test the system. See: Testing and Inspection/Evaporative Emission System Leak Test - Carry out the evaporative emissions repair verification drive cycle. See: Testing and Inspection/Evaporative Emission Repair Verification Drive Cycle Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair Evaporative Emission Control Canister: Service and Repair EVAPORATIVE EMISSION CANISTER Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Page 4650 Part 2 Exploded View Removal and Installation WARNING: - The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery ground cable from the battery to minimize the possibility of an electrical spark occurring, possibly causing a fire or explosion if fuel vapor or liquid fuel are present in the area. Failure to follow these instructions can result in personal injury. - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the spare tire. 4. Disconnect the evaporative emissions (EVAP) canister vent solenoid electrical connector. 5. Disconnect the fuel vapor tube quick connect coupling from the EVAP canister. 6. Disconnect the fuel vapor vent tube from the dust separator. 7. Remove the EVAP canister bolt to side rail. - To install, tighten to 15 Nm (11 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Page 4651 8. Remove the EVAP canister and fuel filler pipe bolt to crossmember. - To install, tighten to 15 Nm (11 lb-ft). 9. Remove the 2 EVAP canister bolts to spare tire carrier. - To install, tighten to 25 Nm (18 lb-ft). 10. Place the EVAP canister bracket assembly on a clean work surface. 11. Disconnect the EVAP canister vent solenoid-to-EVAP canister hose. 12. Disconnect the hose from the dust separator. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Page 4652 13. Release the tabs and remove the EVAP canister from the bracket. 14. To install, reverse the removal procedure. - Leak test the system. See: Testing and Inspection/Evaporative Emission System Leak Test - Carry out the evaporative emissions repair verification drive cycle. See: Testing and Inspection/Evaporative Emission Repair Verification Drive Cycle Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Solenoid, Evaporative System > Component Information > Description and Operation Leak Detection Solenoid: Description and Operation CANISTER VENT (CV) SOLENOID Typical Canister Vent (CV) Solenoid During the evaporative emissions (EVAP) leak check monitor, the CV solenoid seals the EVAP canister from the atmospheric pressure. This allows the EVAP canister purge valve to obtain the target vacuum in the fuel tank during the EVAP leak check monitor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations View 151-36 (Chassis, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations > Page 4659 C4116 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations > Page 4660 Leak Detection Valve: Service and Repair EVAPORATIVE EMISSION CANISTER VENT SOLENOID Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations > Page 4661 Part 2 Exploded View Removal and Installation WARNING: - The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery ground cable from the battery to minimize the possibility of an electrical spark occurring, possibly causing a fire or explosion if fuel vapor or liquid fuel are present in the area. Failure to follow these instructions can result in personal injury. - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the spare tire. 4. Disconnect the evaporative emissions (EVAP) canister vent solenoid electrical connector. 5. Disconnect the fuel vapor tube quick connect coupling from the EVAP canister. 6. Disconnect the fuel vapor vent tube from the dust separator. 7. Remove the EVAP canister bolt to side rail. - To install, tighten to 15 Nm (11 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations > Page 4662 8. Remove the EVAP canister and fuel filler pipe bolt to crossmember. - To install, tighten to 15 Nm (11 lb-ft). 9. Remove the 2 EVAP canister bolts to spare tire carrier. - To install, tighten to 25 Nm (18 lb-ft). 10. Place the EVAP canister bracket assembly on a clean work surface. 11. Disconnect the hoses and remove the EVAP canister vent solenoid from the EVAP canister bracket. 12. To install, reverse the removal procedure. - Carry out the evaporative emission system leak test. See: Testing and Inspection/Evaporative Emission System Leak Test - Carry out the evaporative emissions repair verification drive cycle. See: Testing and Inspection/Evaporative Emission Repair Verification Drive Cycle Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Description and Operation EGR Electronic Vacuum Regulator Solenoid: Description and Operation EXHAUST GAS RECIRCULATION (EGR) VACUUM REGULATOR (EVR) SOLENOID EVR Solenoid Vacuum Output (IN-HG) EVR Solenoid Data The EVR solenoid is an electromagnetic device which is used to regulate the vacuum supply to the EGR valve. The solenoid contains a coil which magnetically controls the position of a disc to regulate the vacuum. As the duty cycle to the coil increases, the vacuum signal passed through the solenoid to the EGR valve also increases. Vacuum not directed to the EGR valve is vented through the solenoid vent to atmosphere. Note that at 0% duty cycle (no electrical signal applied), the EVR solenoid allows some vacuum to pass, but not enough to open the EGR valve. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Description and Operation EGR Tube: Description and Operation EXHAUST GAS RECIRCULATION (EGR) ORIFICE TUBE ASSEMBLY EGR Orifice Tube Assembly The orifice tube assembly is a section of tubing connecting the exhaust system to the intake manifold. The assembly provides the flow path for the EGR to the intake manifold and also contains the metering orifice and 2 pressure pick-up tubes. The internal metering orifice creates a measurable pressure drop across it as the EGR valve opens and closes. This pressure differential across the orifice is picked up by the differential pressure feedback EGR (DPFE) sensor which provides feedback to the powertrain control module (PCM). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Electric Exhaust Gas Recirculation (EEGR) Valve EGR Valve: Description and Operation Electric Exhaust Gas Recirculation (EEGR) Valve ELECTRIC EXHAUST GAS RECIRCULATION (EEGR) VALVE EEGR Motor/Valve Assembly Depending on the application, the EEGR valve is a water cooled or an air cooled motor/valve assembly. The motor is commanded to move in 52 discrete steps as it acts directly on the EEGR valve. The position of the valve determines the rate of EGR. The built-in spring works to close the valve (against the motor opening force). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Electric Exhaust Gas Recirculation (EEGR) Valve > Page 4674 EGR Valve: Description and Operation Exhaust Gas Recirculation (EGR) System Module (ESM) EXHAUST GAS RECIRCULATION (EGR) SYSTEM MODULE (ESM) ESM The ESM is an integrated differential pressure feedback EGR (DPFE) system. It functions in the same manner as the conventional DPFE system, however the various system components have been integrated into a single component called the ESM. The flange of the valve portion of the ESM bolts directly to the intake manifold with a metal gasket that forms the measuring orifice. This arrangement increases system reliability, response time, and system precision. By relocating the EGR orifice from the exhaust to the intake side of the EGR valve, the downstream pressure signal measures manifold absolute pressure (MAP). The system provides the powertrain control module (PCM) with a differential DPFE signal, identical to a traditional DPFE system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Electric Exhaust Gas Recirculation (EEGR) Valve > Page 4675 EGR Valve: Description and Operation Exhaust Gas Recirculation (EGR) Valve EXHAUST GAS RECIRCULATION (EGR) VALVE Typical EGR Valve Test Graph The EGR valve in the differential pressure feedback EGR (DPFE) system is a conventional, vacuum-actuated. The valve increases or decreases the flow of EGR. As vacuum applied to the EGR valve diaphragm overcomes the spring force, the valve begins to open. As the vacuum signal weakens, at 5.4 kPa (1.6 in-Hg) or less, the spring force closes the valve. The EGR valve is fully open at about 15 kPa (4.5 in-Hg). Since EGR flow requirement varies greatly, providing repair specifications on flow rate is impractical. The on-board diagnostic (OBD) system monitors the EGR valve function and triggers a diagnostic trouble code (DTC) if the test criteria is not met. The EGR valve flow rate is not measured directly as part of the diagnostic procedures. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback Exhaust Gas Recirculation (EGR) (DPFE) Sensor Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback Exhaust Gas Recirculation (EGR) (DPFE) Sensor DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) (DPFE) SENSOR DPFE Sensor The DPFE sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through 2 hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the DPFE sensor housing for identification (note that the HI signal uses a larger diameter hose). The DPFE sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the powertrain control module (PCM) as EGR flow rate feedback. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback Exhaust Gas Recirculation (EGR) (DPFE) Sensor > Page 4680 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback Exhaust Gas Recirculation (EGR) (DPFE) Sensor - Tube Mounted DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) (DPFE) SENSOR - TUBE MOUNTED DPFE Sensor - Tube Mounted The tube mounted DPFE sensor is identical in operation as the larger plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Heater > Component Information > Service and Repair PCV Heater: Service and Repair POSITIVE CRANKCASE VENTILATION (PCV) HEATER ELEMENT Removal 1. Disconnect the battery ground cable. 2. Disconnect the positive crankcase ventilation (PCV) heater element electrical connector. 3. Disconnect the quick release couplings and remove the PCV tube. 4. Remove the bolt and the PCV heater element. - Discard the O-ring seal. Installation 1. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation. Using a new O-ring seal, install the PCV heater element and the bolt. Tighten to 10 Nm (89 lb-in). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Heater > Component Information > Service and Repair > Page 4685 2. Position the PCV tube and connect the quick release couplings. 3. Connect the PCV heater element electrical connector. 4. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Diagrams C190 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback Exhaust Gas Recirculation (EGR) (DPFE) Sensor Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback Exhaust Gas Recirculation (EGR) (DPFE) Sensor DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) (DPFE) SENSOR DPFE Sensor The DPFE sensor is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through 2 hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the DPFE sensor housing for identification (note that the HI signal uses a larger diameter hose). The DPFE sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the powertrain control module (PCM) as EGR flow rate feedback. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback Exhaust Gas Recirculation (EGR) (DPFE) Sensor > Page 4694 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback Exhaust Gas Recirculation (EGR) (DPFE) Sensor - Tube Mounted DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) (DPFE) SENSOR - TUBE MOUNTED DPFE Sensor - Tube Mounted The tube mounted DPFE sensor is identical in operation as the larger plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Item....................................................................................................................................................... ..............................................................Specification Fuel Pressure Key on, engine off................................................................................................................................. .............................................240-310 kPa (35-45 psi) Engine running................................................. ..................................................................................................................................193-310 kPa (28-45 psi) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The electrical connector is located on the LH frame rail under the driver side door. Disconnect the electrical connector. 3. Start the engine and allow it to idle until it stalls. 4. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail pressure has been released. 5. Turn the ignition switch to the OFF position. 6. When fuel system service is complete, connect the electrical connector. 7. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 8. Install the diagnostic tool. Turn the key ON with the engine OFF. Cycle the key OFF, then ON. Select the appropriate vehicle and engine qualifier. Clear all diagnostic trouble codes (DTCs) and carry out a PCM reset. 9. Start the vehicle and check the fuel system for leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Measured/PID Values Hot Idle Speed ..................................................................................................................................... ....................................................... 600-650 RPM Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications Torque Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Accelerator Pedal - Fixed Accelerator Pedal: Service and Repair Accelerator Pedal - Fixed ACCELERATOR PEDAL - FIXED Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the accelerator pedal position sensor electrical connector. 3. Remove the 3 bolts and the accelerator pedal assembly. - To install, tighten to 25 Nm (18 lb-ft). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Accelerator Pedal - Fixed > Page 4710 Accelerator Pedal: Service and Repair Accelerator Pedal - Adjustable ACCELERATOR PEDAL - ADJUSTABLE Removal and Installation 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 the all the way rearward position. 1. Disconnect the battery ground cable. 2. Disconnect the accelerator pedal position sensor electrical connector. 3. Remove the 3 nuts and the accelerator pedal assembly. - To install, tighten to 13 Nm (10 lb-ft). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4714 C2040 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4715 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The APP sensor is an input to the powertrain control module (PCM) and is used to determine the torque demand. There are 3 pedal position signals in the sensor. Signal 1, APPS1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, APPS2 and APPS3, both have a positive slope (increasing angle, increasing voltage). During normal operation APPS1 is used as the indication of pedal position by the strategy. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. There are 2 reference voltage circuits and 2 signal return circuits for the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 AIR CLEANER INTAKE PIPE Exploded View Removal and Installation 1. Remove the air cleaner element. 2. Reach into the opening of the air cleaner assembly and depress the locking tab on the air cleaner intake pipe to release the air cleaner intake pipe from the air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 4720 3. Remove the air cleaner intake tube assembly. 4. CAUTION: The air cleaner intake pipe should be securely sealed to prevent unusual engine noise. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair AIR CLEANER ELEMENT Exploded View Removal and Installation 1. Release the retaining clips and remove the air cleaner element tray. 2. Remove the air cleaner element from the air cleaner element tray. 3. CAUTION: The air cleaner element tray must be fully seated to the air cleaner housing. Failure to do so will result in unusual engine noise. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 4727 C1454 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 4728 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW (MAF) SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT Sensor Wire Where Applicable) Terminals Typical Mass Air Flow (MAF) Sensor Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 4729 Typical Drop-in Mass Air Flow (MAF) Sensor The MAF sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above the ambient temperature as measured by a constant cold wire. If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the mass air flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. Most MAF sensors have integrated bypass technology (IBT) with an integrated intake air temperature (IAT) sensor. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 4730 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the mass air flow (MAF) sensor electrical connector. 3. Remove the 2 bolts and the MAF sensor. - To install, tighten to 7 Nm (62 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Specifications Fuel: Specifications Fuel ...................................................................................................................................................... .................................................................. 87 Octane CHOOSING THE RIGHT FUEL Use only UNLEADED FUEL. The use of leaded fuel is prohibited by law and could damage your vehicle. Your vehicle was not designed to use fuel or fuel additives with metallic compounds, including manganese-based additives. Studies indicate that these additives can cause your vehicles emission control system to deteriorate more rapidly. In Canada, premium grade fuel generally contains more metallic additives than regular fuel. We recommend using regular grade fuel. In Canada, many fuels contain metallic additives, but fuels free of such additives may be available; check with your local fuel dealer. Do not use fuel containing methanol. It can damage critical fuel system components. Repairs to correct the effects of using a fuel for which your vehicle was not designed may not be covered by your warranty. OCTANE RECOMMENDATIONS Your vehicle is designed to use "Regular" unleaded gasoline with pump (R+M)/2 octane rating of 87. We do not recommend the use of gasolines labeled as "Regular" that are sold with octane ratings of 86 or lower in high altitude areas. Do not be concerned if your engine sometimes knocks lightly. However, if it knocks heavily under most driving conditions while you are using fuel with the recommended octane rating. FUEL QUALITY If you are experiencing starting, rough idle or hesitation driveability problems, try a different brand of unleaded gasoline. "Premium" unleaded gasoline is not recommended for vehicles designed to use "Regular" unleaded gasoline because it may cause these problems to become more pronounced. It should not be necessary to add any aftermarket products to your fuel tank if you continue to use high quality fuel of the recommended octane rating. Aftermarket products could cause damage to the fuel system. Repairs to correct the effects of using an aftermarket product in your fuel may not be covered by your warranty. Many of the worlds automakers approved the World-wide Fuel Charter that recommends gasoline specifications to provide improved performance and emission control system protection for your vehicle. Gasolines that meet the World-wide Fuel Charter should be used when available. Ask your fuel supplier about gasolines that meet the World-wide Fuel Charter. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap Warning Indicator > Component Information > Description and Operation Fuel Filler Cap Warning Indicator: Description and Operation CHECK FUEL CAP INDICATOR NOTE: The check fuel cap indicator on the Hanger is a dedicated output signal that is controlled by the PCM. The check fuel cap indicator is a communications network message sent by the PCM. The PCM sends the message to illuminate the lamp when the strategy determines that there is a failure in the vapor management system due to the fuel filler cap not being sealed correctly. This would be detected by the inability to pull vacuum in the fuel tank, after a fueling event. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The electrical connector is located on the LH frame rail under the driver side door. Disconnect the electrical connector. 3. Start the engine and allow it to idle until it stalls. 4. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail pressure has been released. 5. Turn the ignition switch to the OFF position. 6. When fuel system service is complete, connect the electrical connector. 7. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 8. Install the diagnostic tool. Turn the key ON with the engine OFF. Cycle the key OFF, then ON. Select the appropriate vehicle and engine qualifier. Clear all diagnostic trouble codes (DTCs) and carry out a PCM reset. 9. Start the vehicle and check the fuel system for leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications Fuel Injector: Electrical Specifications Fuel Injector Resistance ...................................................................................................................... ............................................................. 11 - 18 Ohms Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications > Page 4745 Fuel Injector: Pressure, Vacuum and Temperature Specifications Fuel Injector Flow and Leakage ........................................................................................ Refer to Pinpoint Test HC7 at Computers and Control Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 C181 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 4748 C182 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 4749 C183 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 4750 C184 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 4751 Fuel Injector: Diagrams C181 C182 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 4752 C183 C184 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 4753 C185 C186 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 4754 C187 C188 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 4755 Fuel Injector: Description and Operation FUEL INJECTORS Fuel Injectors CAUTION: Do not apply battery positive voltage (B+) directly to the fuel injector electrical connector terminals. The solenoids may be damaged internally in a matter of seconds. The fuel injector is a solenoid-operated valve that meters fuel flow to the engine. The fuel injector is opened and closed a constant number of times per crankshaft revolution. The amount of fuel is controlled by the length of time the fuel injector is held open. The fuel injector is normally closed, and is operated by 12-volt VPWR from the electronic engine control power relay. The ground signal is controlled by the PCM. The injector is the deposit resistant injector (DRI) type and does not have to be cleaned. However, it can be flow checked and, if found outside of specification, a new fuel injector should be installed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 4756 Fuel Injector: Service and Repair FUEL INJECTORS Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 4757 Part 2 Exploded View Special Tool(s) Special Tool(s) Removal and Installation WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel tubes or fuel system components, the fuel system pressure must be relieved. Failure to follow these instructions may result in personal injury. - 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. CAUTION: - Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or tubes. - When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube. 1. Disconnect the fuel supply tube spring lock coupling. 2. Disconnect the battery ground cable. 3. Remove the air cleaner inlet pipe. 4. Disconnect the mass air flow (MAF) sensor electrical connector. 5. Disconnect the brake booster vacuum hose. 6. Disconnect the positive crankcase ventilation (PCV) tube. 7. Disconnect the crankcase ventilation tube. 8. Disconnect the 8 fuel injector electrical connectors. 9. Remove the 8 fuel injector-to-fuel rail locking clips 10. Remove the 4 fuel rail bolts and the fuel rail. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 4758 - To install, tighten to 10 Nm (89 lb-in). 11. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals. NOTE: Lubricate the O-ring seals with clean engine oil prior to installation. Remove the fuel injectors and the fuel injector O-ring seals. Discard the O-ring seals. 12. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings Fuel Line Coupler: Service and Repair Spring Lock Couplings SPRING LOCK COUPLINGS Special Tool(s) Special Tool(s) Disconnect WARNING: - Do not smoke, carry lighted tobacco or have open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. - This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury. - 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. Failure to follow these instructions may result in personal injury. CAUTION: - When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube. Apply clean engine oil to the end of the tube before inserting the tube into the connector. - Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or tubes. NOTE: These couplings are used to connect the fuel hoses to the fuel supply manifold. 1. Release the fuel system pressure. 2. Remove the fuel tube safety clip. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 4763 3. Install the special tool. 4. Close and push the special tool into the open side of the cage. 5. Separate the fitting. Connect CAUTION: Make sure the fuel tube clicks into place when installing the tube. To make sure that the fuel tube is fully seated, pull on the tube. 1. Inspect and clean both coupling ends. Install new O-ring seals and garter springs if necessary. - Lubricate the O-ring seals with clean engine oil. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 4764 2. Fit the male fitting into the female end and push until the garter spring snaps over the flared end of the female fitting. 3. Make sure the coupling is engaged by pulling on the lines and install the fuel tube safety clip. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 4765 Fuel Line Coupler: Service and Repair Vapor Tube Fittings VAPOR TUBE FITTINGS Disconnect 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. Failure to follow these instructions may result in personal injury. - Do not smoke, carry lighted tobacco or have open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. CAUTION: - When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube. Apply clean engine oil to the end of the tube before inserting the tube into the connector. - Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or tubes. NOTE: If the fuel tube retainer clip is broken or damaged, install a new clip using a suitable fuel line disconnect tool to separate the retaining clip legs. Once the retainer legs have been separated, lift the clip out of the connector housing, lifting from the stamped side of the connector body. 1. Disconnect the battery ground cable. 2. Disconnect the vapor tube fitting. - Push the connector toward the tube or fitting to release pressure. - Press the quick connect fitting button and pull the fuel tube to disconnect. Connect CAUTION: Make sure the quick connect fitting clicks into place when installing the tube. To make sure that the quick connect fitting is fully seated, pull on the tube. NOTE: If the fuel tube retainer clip is broken or damaged, install a new clip using a suitable fuel line disconnect tool to separate the retaining clip legs. Once the retainer legs have been separated, lift the clip out of the connector housing, lifting from the stamped side of the connector body. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 4766 1. NOTE: Apply clean engine oil to the end of the tube or fitting before connecting. Connect the quick connect fitting. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 4767 Fuel Line Coupler: Service and Repair Quick Connect Coupling QUICK CONNECT COUPLING Disconnect - Type 1 WARNING: - Do not smoke, carry lighted tobacco or have open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. CAUTION: - When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube. Apply clean engine oil to the end of the tube before inserting the tube into the connector. - Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or tubes. 1. Disconnect the quick connect fitting. - Push the connector toward the tube to release pressure. - Push the release tab clockwise. - Disconnect the quick connect fitting. Connect - Type 1 CAUTION: Make sure the fuel tube clicks into place when installing the tube. To make sure that the fuel tube is fully seated, pull on the tube. 1. NOTE: Apply clean engine oil to the end of the tube or fitting before connecting. Connect the quick connect fitting. Disconnect - Type 2 WARNING: - Do not smoke, carry lighted tobacco or have open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 4768 fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. - This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury. - 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. Failure to follow these instructions may result in personal injury. CAUTION: - When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube. Apply clean engine oil to the end of the tube before inserting the tube into the connector. - Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or tubes. NOTE: These couplings are used to connect the fuel tank fuel lines to the front fuel lines and the pump/sender assembly ports. 1. Release the fuel system pressure. 2. Press the tab corners to release the locking tab. 3. Pull the locking tab to the release position. 4. Disconnect the quick connect fitting. - Push the fitting toward the tube to release pressure. - Press the tab corners to release the fitting. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 4769 - Disconnect the quick connect fitting. Connect - Type 2 CAUTION: Make sure the fuel tube clicks into place when installing the tube. To make sure that the fuel tube is fully seated, pull on the tube. NOTE: If the fuel tube retainer clip is broken or damaged, install a new clip using a suitable fuel line disconnect tool to separate the retaining clip legs. Once the retainer legs have been separated, lift the clip out of the connector housing, lifting from the stamped side of the connector body. 1. NOTE: Apply clean engine oil to the end of the tube or fitting before connecting. Connect the tube into the quick connect fitting. 2. CAUTION: Make sure the quick connect fitting clicks into place when installing the tube. To make sure that the quick connect fitting is fully seated, pull on the fitting. Press the locking tab down into the locked position. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Fuel Rail Pressure Sensor View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Fuel Rail Pressure Sensor > Page 4774 View 151-36 (Chassis, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Fuel Rail Pressure/Temperature Sensor C1475 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Fuel Rail Pressure/Temperature Sensor > Page 4777 C435 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation > Fuel Rail Pressure (FRP) Sensor Fuel Pressure Sensor/Switch: Description and Operation Fuel Rail Pressure (FRP) Sensor FUEL RAIL PRESSURE (FRP) SENSOR Fuel Rail Pressure (FRP) Sensor The FRP sensor is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and the resistance decreases as the pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation > Fuel Rail Pressure (FRP) Sensor > Page 4780 Fuel Pressure Sensor/Switch: Description and Operation Fuel Rail Pressure Temperature (FRPT) Sensor FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR Typical Fuel Rail Pressure Temperature (FRPT) Sensor The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to determine the pressure difference between the fuel rail and the intake manifold. The relationship between fuel pressure and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. Both pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation > Page 4781 Fuel Pressure Sensor/Switch: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE (FRPT) SENSOR Removal and Installation WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before 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. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel rail pressure and temperature (FRPT) sensor electrical and vacuum connectors. 4. Remove the 2 bolts and the FRPT sensor and discard the O-ring seal. - To install, tighten to 10 Nm (89 lb-in). - Install a new O-ring seal. - Lubricate the new O-ring seal prior to installation. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Description and Operation Fuel Pressure Pulsation Damper: Description and Operation FUEL RAIL PULSE DAMPER Typical Fuel Rail Pulse Damper The fuel rail pulse damper is located on the fuel rail and reduces the fuel system noise caused by the pulsing of the fuel injectors. The vacuum port located on the damper is connected to manifold vacuum to avoid fuel spillage if the pulse damper diaphragm ruptures. The fuel rail pulse damper should not be confused with a fuel pressure regulator; it does not regulate the fuel rail pressure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Item....................................................................................................................................................... ..............................................................Specification Fuel Pressure Key on, engine off................................................................................................................................. .............................................240-310 kPa (35-45 psi) Engine running................................................. ..................................................................................................................................193-310 kPa (28-45 psi) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control Unit > Component Information > Locations View 151-36 (Chassis, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control Unit > Component Information > Locations > Page 4792 C4033 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control Unit > Component Information > Locations > Page 4793 Fuel Pump Control Unit: Service and Repair Fuel Pump Driver Module (FPDM) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. NOTE: The fuel pump driver module (FPDM) is located on the top of the LH frame rail near the fuel tank filler pipe. Disconnect the FPDM electrical connector. 4. Remove the bolts and the FPDM. - To install, tighten to 10 Nm (89 lb-in). 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 4797 View 151-1 (Engine Compartment) The fuel pump relay is located in the Central Junction Box (CJB) and is Not Serviceable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair Fuel Rail: Service and Repair FUEL RAIL Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Page 4801 Part 2 Exploded View Special Tool(s) Special Tool(s) Removal and Installation WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel tubes or fuel system components, the fuel system pressure must be relieved. Failure to follow these instructions may result in personal injury. - 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. CAUTION: - Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or tubes. - When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube. 1. Disconnect the fuel supply tube spring lock coupling. 2. Disconnect the battery ground cable. 3. Remove the air cleaner inlet pipe. 4. Disconnect the mass air flow (MAF) sensor electrical connector. 5. Disconnect the brake booster vacuum hose. 6. Disconnect the positive crankcase ventilation (PCV) tube. 7. Disconnect the crankcase ventilation tube. 8. Disconnect the fuel rail pressure and temperature sensor electrical and vacuum connectors. 9. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Page 4802 Remove the 2 bolts and the fuel rail pressure and temperature sensor. Discard the O-ring seal. - To install, tighten to 4 Nm (35 lb-in). 10. Disconnect the 8 fuel injector electrical connectors. 11. Remove the 8 fuel injector-to-fuel rail locking clips. 12. Remove the 4 fuel rail bolts and the fuel rail. - To install, tighten to 10 Nm (89 lb-in). 13. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals. Lubricate the O-ring seals with clean engine oil prior to installation. Remove the fuel injectors and the fuel injector O-ring seals. Discard the O-ring seals. 14. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair Fuel Supply Line: Service and Repair FUEL LINES Exploded View Removal and Installation WARNING: - Do not smoke, carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Page 4806 mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel tubes or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard. CAUTION: - Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or tubes. - When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Release the fuel system pressure. 3. Disconnect the fuel filter outlet tube spring lock coupling. 4. Disconnect the fuel tube-to-fuel rail spring lock coupling. 5. Disconnect the fuel tube from the position retainer brackets and remove the fuel tube assembly. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair Fuel Filler Hose: Service and Repair FUEL TANK FILLER PIPE Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Page 4811 Part 2 Exploded View Removal and Installation WARNING: - Do not smoke, carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel tubes or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard. CAUTION: - Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or tubes. - When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the fuel tank filler cap. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Page 4812 4. Remove the 3 screws. 5. Disconnect the fuel tank filler pipe vent tube from the fuel pump module. 6. Loosen the hose clamp and disconnect the fuel tank filler pipe-to-fuel tank hose. 7. Disconnect the vapor tube from the evaporative emissions (EVAP) system dust separator. 8. Remove the 2 bolts from the fuel tank filler pipe support bracket. - To install, tighten to 15 Nm (11 lb-ft). 9. Remove the fuel tank filler pipe assembly. 10. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump (FP) Module Fuel Gauge Sender: Description and Operation Fuel Pump (FP) Module FUEL PUMP (FP) MODULE Mechanical Returnless Fuel Pump Module (FPM) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump (FP) Module > Page 4817 Electronic Returnless Fuel Pump Module (FPM) The FP module is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump (FP) Module > Page 4818 Fuel Gauge Sender: Description and Operation Fuel Pump Module and Reservoir FUEL PUMP MODULE AND RESERVOIR Fuel Pump Module And Reservoir The fuel pump module is mounted inside the fuel tank in a reservoir. The pump has a discharge check valve that maintains the system pressure after the ignition key has been turned off to minimize starting concerns. The reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low tank fill levels. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Page 4819 Fuel Gauge Sender: Service and Repair FUEL PUMP MODULE Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Page 4820 Part 2 Exploded View Special Tool(s) Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Page 4821 Removal and Installation WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. 1. Remove the fuel tank. 2. Disconnect the fuel and vapor tubes from the fuel pump module. 3. Using the special tool, remove the fuel pump lock ring. 4. CAUTION: Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Page 4822 - Note the location of the fuel pump alignment tabs. - Carefully remove the fuel pump assembly to avoid damaging the fuel level sensor. Remove the fuel pump module assembly. Remove and discard the O-ring seal. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams C433 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Description and Operation > Fuel Pump (FP) Module Fuel Tank Unit: Description and Operation Fuel Pump (FP) Module FUEL PUMP (FP) MODULE Mechanical Returnless Fuel Pump Module (FPM) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Description and Operation > Fuel Pump (FP) Module > Page 4828 Electronic Returnless Fuel Pump Module (FPM) The FP module is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Description and Operation > Fuel Pump (FP) Module > Page 4829 Fuel Tank Unit: Description and Operation Fuel Pump Module and Reservoir FUEL PUMP MODULE AND RESERVOIR Fuel Pump Module And Reservoir The fuel pump module is mounted inside the fuel tank in a reservoir. The pump has a discharge check valve that maintains the system pressure after the ignition key has been turned off to minimize starting concerns. The reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low tank fill levels. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 4833 C1475 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation > Fuel Rail Pressure Temperature (FRPT) Sensor Fuel Temperature Sensor: Description and Operation Fuel Rail Pressure Temperature (FRPT) Sensor FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR Typical Fuel Rail Pressure Temperature (FRPT) Sensor The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to determine the pressure difference between the fuel rail and the intake manifold. The relationship between fuel pressure and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. Both pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation > Fuel Rail Pressure Temperature (FRPT) Sensor > Page 4836 Fuel Temperature Sensor: Description and Operation Fuel Rail Temperature (FRT) Sensor FUEL RAIL TEMPERATURE (FRT) SENSOR Fuel Rail Temperature (FRT) Sensor The FRT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRT sensor measures the temperature of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation > Page 4837 Fuel Temperature Sensor: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE (FRPT) SENSOR Removal and Installation WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before 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. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel rail pressure and temperature (FRPT) sensor electrical and vacuum connectors. 4. Remove the 2 bolts and the FRPT sensor and discard the O-ring seal. - To install, tighten to 10 Nm (89 lb-in). - Install a new O-ring seal. - Lubricate the new O-ring seal prior to installation. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation Idle Speed/Throttle Actuator - Electronic: Description and Operation IDLE AIR CONTROL (IAC) VALVE NOTE: The IAC valve assembly is not adjustable and cannot be cleaned, also some IAC valves are normally open and others are normally closed. Some IAC valves require engine vacuum to operate. The IAC valve assembly controls the engine idle speed and provides a dashpot function. The IAC valve assembly meters intake air around the throttle plate through a bypass within the IAC valve assembly and throttle body. The PCM determines the desired idle speed or bypass air and signals the IAC valve assembly through a specified duty cycle. The IAC valve responds by positioning the IAC valve to control the amount of bypassed air. The PCM monitors engine RPM and increases or decreases the IAC duty cycle in order to achieve the desired RPM. The PCM uses the IAC valve assembly to control: - no touch start - cold engine fast idle for rapid warm-up - idle (corrects for engine load) - stumble or stalling on deceleration (provides a dashpot function) - over-temperature idle boost Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations View 151-19 (Left Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 4844 C4168 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 4845 Inertia Fuel Shutoff Switch: Description and Operation INERTIA FUEL SHUTOFF (IFS) SWITCH Typical Inertia Fuel Shutoff (IFS) Switch The IFS switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shutoff the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner's Literature for the location of the IFS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 4846 Inertia Fuel Shutoff Switch: Service and Repair INERTIA FUEL SHUTOFF (IFS) SWITCH Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the LH rear interior quarter trim panel. 3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Remove the 2 bolts and the IFS switch. - To install, tighten to 10 Nm (89 lb-in). 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4850 C2160 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4851 Main Relay (Computer/Fuel System): Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4852 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations View 151-36 (Chassis, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 4857 C4033 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 4858 Fuel Pump Control Unit: Service and Repair Fuel Pump Driver Module (FPDM) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. NOTE: The fuel pump driver module (FPDM) is located on the top of the LH frame rail near the fuel tank filler pipe. Disconnect the FPDM electrical connector. 4. Remove the bolts and the FPDM. - To install, tighten to 10 Nm (89 lb-in). 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 (V8-5.4L VIN 5 (2006)) 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 4862 View 151-1 (Engine Compartment) The fuel pump relay is located in the Central Junction Box (CJB) and is Not Serviceable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 4866 C2160 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 4867 Main Relay (Computer/Fuel System): Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 4868 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4873 C2040 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4874 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The APP sensor is an input to the powertrain control module (PCM) and is used to determine the torque demand. There are 3 pedal position signals in the sensor. Signal 1, APPS1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, APPS2 and APPS3, both have a positive slope (increasing angle, increasing voltage). During normal operation APPS1 is used as the indication of pedal position by the strategy. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. There are 2 reference voltage circuits and 2 signal return circuits for the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 4878 C1454 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 4879 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW (MAF) SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT Sensor Wire Where Applicable) Terminals Typical Mass Air Flow (MAF) Sensor Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 4880 Typical Drop-in Mass Air Flow (MAF) Sensor The MAF sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above the ambient temperature as measured by a constant cold wire. If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the mass air flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. Most MAF sensors have integrated bypass technology (IBT) with an integrated intake air temperature (IAT) sensor. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 4881 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the mass air flow (MAF) sensor electrical connector. 3. Remove the 2 bolts and the MAF sensor. - To install, tighten to 7 Nm (62 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Fuel Rail Pressure Sensor View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Fuel Rail Pressure Sensor > Page 4886 View 151-36 (Chassis, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Fuel Rail Pressure/Temperature Sensor C1475 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Fuel Rail Pressure/Temperature Sensor > Page 4889 C435 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation > Fuel Rail Pressure (FRP) Sensor Fuel Pressure Sensor/Switch: Description and Operation Fuel Rail Pressure (FRP) Sensor FUEL RAIL PRESSURE (FRP) SENSOR Fuel Rail Pressure (FRP) Sensor The FRP sensor is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and the resistance decreases as the pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation > Fuel Rail Pressure (FRP) Sensor > Page 4892 Fuel Pressure Sensor/Switch: Description and Operation Fuel Rail Pressure Temperature (FRPT) Sensor FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR Typical Fuel Rail Pressure Temperature (FRPT) Sensor The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to determine the pressure difference between the fuel rail and the intake manifold. The relationship between fuel pressure and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. Both pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation > Page 4893 Fuel Pressure Sensor/Switch: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE (FRPT) SENSOR Removal and Installation WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before 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. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel rail pressure and temperature (FRPT) sensor electrical and vacuum connectors. 4. Remove the 2 bolts and the FRPT sensor and discard the O-ring seal. - To install, tighten to 10 Nm (89 lb-in). - Install a new O-ring seal. - Lubricate the new O-ring seal prior to installation. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 4897 C1475 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation > Fuel Rail Pressure Temperature (FRPT) Sensor Fuel Temperature Sensor: Description and Operation Fuel Rail Pressure Temperature (FRPT) Sensor FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR Typical Fuel Rail Pressure Temperature (FRPT) Sensor The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to determine the pressure difference between the fuel rail and the intake manifold. The relationship between fuel pressure and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. Both pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation > Fuel Rail Pressure Temperature (FRPT) Sensor > Page 4900 Fuel Temperature Sensor: Description and Operation Fuel Rail Temperature (FRT) Sensor FUEL RAIL TEMPERATURE (FRT) SENSOR Fuel Rail Temperature (FRT) Sensor The FRT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRT sensor measures the temperature of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation > Page 4901 Fuel Temperature Sensor: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE (FRPT) SENSOR Removal and Installation WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before 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. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel rail pressure and temperature (FRPT) sensor electrical and vacuum connectors. 4. Remove the 2 bolts and the FRPT sensor and discard the O-ring seal. - To install, tighten to 10 Nm (89 lb-in). - Install a new O-ring seal. - Lubricate the new O-ring seal prior to installation. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations View 151-19 (Left Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 4905 C4168 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 4906 Inertia Fuel Shutoff Switch: Description and Operation INERTIA FUEL SHUTOFF (IFS) SWITCH Typical Inertia Fuel Shutoff (IFS) Switch The IFS switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shutoff the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner's Literature for the location of the IFS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 4907 Inertia Fuel Shutoff Switch: Service and Repair INERTIA FUEL SHUTOFF (IFS) SWITCH Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the LH rear interior quarter trim panel. 3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Remove the 2 bolts and the IFS switch. - To install, tighten to 10 Nm (89 lb-in). 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 4911 C189 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Electronic Throttle Body (ETB) Position Sensor Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR The ETB position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB position signals are required for increased monitoring. The first ETB position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). During normal operation the negative slope ETB position sensor signal (TP1) is used by the control strategy as the indication of throttle position. The 2 ETB position sensor signals make sure the PCM receives a correct input even if 1 signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Electronic Throttle Body (ETB) Position Sensor > Page 4914 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor THROTTLE POSITION (TP) SENSOR Typical TP Sensor The TP sensor is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a 3-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 4915 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Removal 1. Disconnect the battery ground cable. 2. Remove the air cleaner inlet pipe and the air cleaner assembly. 3. Disconnect the throttle position (TP) sensor electrical connector. 4. CAUTION: Failure to remove the TP sensor screws in the following manner will result in damage to the screws. First loosen the screws 1-2 full turns using a hand tool and then use a suitable high speed driver to complete the removal. Remove and discard the 2 screws and the TP sensor. Installation 1. CAUTION: - Do not reuse the TP sensor and screws. A new TP sensor and screws must be installed. - Do not use a high speed driver to install the new screws or damage to the TP sensor can occur. NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor is aligned with the radial locator hole on the throttle body. Position the new TP sensor and install the 2 new screws. Tighten to 3 Nm (27 lb-in). 2. Connect the TP sensor electrical connector. 3. Install the air cleaner and air cleaner inlet pipe. 4. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair Throttle Body: Service and Repair THROTTLE BODY Removal 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. CAUTION: The throttle body bore and plate area have a special coating and cannot be cleaned. 1. Disconnect the battery ground cable. 2. Remove the air cleaner assembly. 3. Disconnect the electronic throttle control electrical connector. 4. Disconnect the throttle position (TP) sensor electrical connector. 5. Remove the 4 bolts and the throttle body (TB) assembly. - Discard the TB O-ring seal. Installation 1. Using a new O-ring seal, install the TB and tighten the 4 bolts in 2 stages. - Stage 1: Tighten to 9 Nm (80 lb-in). - Stage 2: Tighten an additional 90 degrees. 2. Connect the TP sensor electrical connector. 3. Connect the electronic throttle control electrical connector. 4. Install the air cleaner assembly. 5. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 4922 C189 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Electronic Throttle Body (ETB) Position Sensor Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR The ETB position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB position signals are required for increased monitoring. The first ETB position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). During normal operation the negative slope ETB position sensor signal (TP1) is used by the control strategy as the indication of throttle position. The 2 ETB position sensor signals make sure the PCM receives a correct input even if 1 signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Electronic Throttle Body (ETB) Position Sensor > Page 4925 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor THROTTLE POSITION (TP) SENSOR Typical TP Sensor The TP sensor is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a 3-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 4926 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Removal 1. Disconnect the battery ground cable. 2. Remove the air cleaner inlet pipe and the air cleaner assembly. 3. Disconnect the throttle position (TP) sensor electrical connector. 4. CAUTION: Failure to remove the TP sensor screws in the following manner will result in damage to the screws. First loosen the screws 1-2 full turns using a hand tool and then use a suitable high speed driver to complete the removal. Remove and discard the 2 screws and the TP sensor. Installation 1. CAUTION: - Do not reuse the TP sensor and screws. A new TP sensor and screws must be installed. - Do not use a high speed driver to install the new screws or damage to the TP sensor can occur. NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor is aligned with the radial locator hole on the throttle body. Position the new TP sensor and install the 2 new screws. Tighten to 3 Nm (27 lb-in). 2. Connect the TP sensor electrical connector. 3. Install the air cleaner and air cleaner inlet pipe. 4. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Actuator > Component Information > Diagrams C1442 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Actuator > Component Information > Diagrams > Page 4931 Variable Induction Control Actuator: Description and Operation INTAKE MANIFOLD TUNING VALVE (IMTV) WARNING: Substantial opening and closing torque is applied by this system. To prevent injury, be careful to keep fingers away from lever mechanisms when actuated. The IMTV is a motorized actuated unit mounted directly to the intake manifold. The IMTV actuator controls a shutter device attached to the actuator shaft. There is no monitor input to the PCM with this system to indicate shutter position. The motorized IMTV unit is not energized below approximately 2,600 RPM. The shutter is in the closed position not allowing airflow blend to occur in the intake manifold. Above approximately 2,600 RPM the motorized unit is energized. The motorized unit is commanded on by the PCM initially at a 100 percent duty cycle to move the shutter to the open position, and then falling to approximately 50 percent to continue to hold the shutter open. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Actuator > Component Information > Diagrams > Page 4932 Variable Induction Control Actuator: Service and Repair CHARGE MOTION CONTROL VALVE (CMCV) Removal and Installation 1. Remove the intake manifold. 2. Disconnect the charge motion control valve (CMCV) RH and LH rods from the intake manifold. 3. Remove the stud bolt, the 2 bolts and the CMCV. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications Firing order........................................................................................................................................... ......................................................... 1-3-7-2-6-5-4-8 Eight separate ignition coils: - are mounted directly above each spark plug. - are controlled by the powertrain control module (PCM) for correct firing sequence. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Item ...................................................................................................................................................... ............................................................ Specification Firing order........................................................................................................................................... ......................................................... 1-3-7-2-6-5-4-8 Eight separate ignition coils: - are mounted directly above each spark plug. - are controlled by the powertrain control module (PCM) for correct firing sequence. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1 C1366 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1 > Page 4946 C1367 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 4947 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR Typical Synchronizer Hall-Effect CMP Sensor Typical Variable Reluctance CMP Sensor The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston No. 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to select the correct ignition coil to fire. Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor and the 2-pin connector variable reluctance type sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 4948 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the camshaft position (CMP) sensor electrical connector. 3. Remove the bolt and the CMP sensor. Discard the O-ring seal. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4952 C101 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4953 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Typical Crankshaft Position (CKP) Sensor The CKP sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L 10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4954 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the accessory drive belt. 4. Disconnect the A/C compressor electrical connector. 5. Remove the 3 bolts and position the A/C compressor aside. - To install, tighten to 25 Nm (18 lb-ft). 6. Disconnect the crankshaft position (CKP) sensor electrical connector. 7. Remove the bolt and the CKP sensor. Discard the O-ring seal. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the new O-ring seal with clean engine oil prior to installation. 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4959 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4960 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4961 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4962 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4963 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4964 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 4965 Torque Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil on Plug 1 C111 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil on Plug 1 > Page 4968 C112 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil on Plug 1 > Page 4969 C113 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil on Plug 1 > Page 4970 C114 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil on Plug 1 > Page 4971 Ignition Coil: Diagrams C111 C112 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil on Plug 1 > Page 4972 C113 C114 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil on Plug 1 > Page 4973 C115 C116 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil on Plug 1 > Page 4974 C117 C118 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil on Plug 1 > Page 4975 C174 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Description and Operation > Engine Ignition Ignition Coil: Description and Operation Engine Ignition ENGINE IGNITION The electronic ignition system is a coil-on-plug ignition system. The coil-on-plug ignition system consists of the following components: - Crankshaft position (CKP) sensor - Ignition coils - Spark plugs The CKP sensor: - is a variable reluctance sensor. - is triggered by a 36-minus-1 tooth sensor ring mounted on the crankshaft. - provides base timing and crankshaft speed (rpm) to the powertrain control module (PCM). The 8 separate ignition coils: - change low voltage signals from the PCM to high voltage pulses. - produce the high voltage pulses to the spark plugs. - are connected directly to each spark plug. The spark plugs: - change high voltage pulses into a spark which ignites the fuel and air mixture. - originally equipped on the vehicle have a platinum-enhanced active electrode for long life. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Description and Operation > Engine Ignition > Page 4978 Ignition Coil: Description and Operation Coil On Plug (COP) COIL ON PLUG (COP) Coil On Plug (COP) The COP ignition operates similar to a standard coil pack ignition except each plug has one coil per plug. The COP has 3 different modes of operation: engine crank, engine running, and CMP failure mode effects management (FMEM). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Description and Operation > Engine Ignition > Page 4979 Ignition Coil: Description and Operation Coil Pack COIL PACK Typical Six-Tower Coil Pack Horizontal Connector 6-Tower Coil Pack Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Description and Operation > Engine Ignition > Page 4980 Series 5 6-Tower Coil Pack Four-Tower Coil Packs The PCM provides a grounding switch for the coil primary circuit. When the switch is closed, voltage is applied to the coil primary circuit. This creates a Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Description and Operation > Engine Ignition > Page 4981 magnetic field around the primary coil. The PCM opens the switch, causing the magnetic field to collapse, inducing the high voltage in the secondary coil windings and firing the spark plug. The spark plugs are paired so that as one spark plug fires on the compression stroke, the other spark plug fires on the exhaust stroke. The next time the coil is fired the order is reversed. The next pair of spark plugs fire according to the engine firing order. Coil packs come in 4-tower, 6-tower horizontal and series 5 6-tower models. Two adjacent coil towers share a common coil and are called a matched pair. For 6-tower coil pack (6 cylinder) applications, the matched pairs are 1 and 5, 2 and 6, and 3 and 4. For 4-tower coil pack (4 cylinder) applications, the matched pairs are 1 and 4, and 2 and 3. When the coil is fired by the PCM, spark is delivered through the matched pair towers to their respective spark plugs. The spark plugs are fired simultaneously and are paired so that as one fires on the compression stroke, the other spark plug fires on the exhaust stroke. The next time the coil is fired, the situation is reversed. The next pair of spark plugs fire according to the engine firing order. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Description and Operation > Page 4982 Ignition Coil: Service and Repair IGNITION COIL-ON-PLUG Engine Ignition - RH Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Description and Operation > Page 4983 Engine Ignition - LH Exploded View Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the ignition coil electrical connector. 3. Remove the bolt and the ignition coil. - Remove the ignition coil, using a twisting motion while pulling up on the ignition coil. - To install, tighten to 6 Nm (53 lb-in). 4. NOTE: Verify that the ignition coil spring is correctly located inside the ignition coil boot and that there is no damage to the tip of the boot. To install, reverse the removal procedure. Apply a light coat of dielectric compound to the inside of the ignition coil boots. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 C109 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 4989 C108 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Page 4990 Knock Sensor: Description and Operation KNOCK SENSOR (KS) Two Types Of Knock Sensor (KS) The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Page 4991 Knock Sensor: Service and Repair KNOCK SENSOR (KS) Removal and Installation 1. Remove the intake manifold. 2. Disconnect the knock sensor (KS) electrical connectors. 3. Remove the 2 bolts and the 2 knock sensors. - To install, tighten to 20 Nm (15 lb-ft). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1 C1366 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1 > Page 4998 C1367 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 4999 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR Typical Synchronizer Hall-Effect CMP Sensor Typical Variable Reluctance CMP Sensor The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston No. 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to select the correct ignition coil to fire. Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor and the 2-pin connector variable reluctance type sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 5000 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the camshaft position (CMP) sensor electrical connector. 3. Remove the bolt and the CMP sensor. Discard the O-ring seal. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the O-ring seal with clean engine oil prior to installation. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 5004 C101 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 5005 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Typical Crankshaft Position (CKP) Sensor The CKP sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L 10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 5006 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the accessory drive belt. 4. Disconnect the A/C compressor electrical connector. 5. Remove the 3 bolts and position the A/C compressor aside. - To install, tighten to 25 Nm (18 lb-ft). 6. Disconnect the crankshaft position (CKP) sensor electrical connector. 7. Remove the bolt and the CKP sensor. Discard the O-ring seal. - To install, tighten to 10 Nm (89 lb-in). - Lubricate the new O-ring seal with clean engine oil prior to installation. 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Locations View 151-14 (Steering Column) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions Ignition Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5012 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5013 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5014 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5015 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5016 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5017 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5018 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5019 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5020 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5021 Ignition Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5022 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5023 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5024 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5025 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5026 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5027 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5028 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5029 C250 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Page 5030 Ignition Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Page 5031 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Page 5032 Ignition Switch: Service and Repair Ignition Switch Ignition Switch Removal and Installation 1. Remove the steering wheel. 2. NOTE: Lower tilt release handle to access second screw. Remove the lower steering column shroud. ^ Remove the screws. 3. NOTE: The screw is located behind the multi-function switch. Remove the screw and the upper steering column shroud. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Page 5033 4. Remove the bolt, push the release and position the multi-function switch aside. 5. Disconnect the ignition switch electrical connector. 6. Remove the ignition switch. 7. To install, reverse the removal procedure. ^ Make sure that the spring located under the ignition switch is positioned on the steering column lock rod. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations View 151-5 (Engine, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 C109 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 1 > Page 5039 C108 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 5040 Knock Sensor: Description and Operation KNOCK SENSOR (KS) Two Types Of Knock Sensor (KS) The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 5041 Knock Sensor: Service and Repair KNOCK SENSOR (KS) Removal and Installation 1. Remove the intake manifold. 2. Disconnect the knock sensor (KS) electrical connectors. 3. Remove the 2 bolts and the 2 knock sensors. - To install, tighten to 20 Nm (15 lb-ft). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions Spark Plug: Technical Service Bulletins Ignition System - Spark Plug Removal Instructions TSB 08-7-6 04/14/08 SPARK PLUG REMOVAL INSTRUCTIONS - 4.6L 3V/5.4L 3V16.8L 3V FORD: 2005-2008 Mustang 2004-2008 F-150 2005-2008 Expedition, F-Super Duty 2006-2008 Explorer, F-53 Motorhome Chassis 2007-2008 Explorer Sport Trac LINCOLN: 2005-2008 Navigator 2006-2008 Mark LT MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-1-9 to update Vehicle Applications, Service Procedure and Part List. ISSUE Some 2004-2008 F-150, 2006-2008 Mark LT, 2005-2008 F-Super Duty, Expedition, and Navigator, with 5.4L 3-V engine; 2005-2008 Mustang, 2006-2008 Explorer, Mountaineer, and 2007-2008 Explorer Sport Trac with 4.6L 3-V engine; 2005-2008 F-Super Duty, 2006-2008 and F-Stripped Chassis, with 6.8L 3-V engine may experience difficulty with spark plug removal. This may cause damage to the spark plug and leave part of the spark plug in the cylinder head. Affected engine build dates are as follows: 5.4L 3-V and 6.8L 3-V before 10/9/07, 4.6L 3-V before 11/30/07. ACTION Refer to the following Service Procedure for techniques to remove the spark plugs and extract broken spark plugs. SERVICE PROCEDURE The engine build date can be read on the left hand cam cover information sticker. To remove spark plugs without damage, it is necessary to adhere exactly to this procedure before removal is attempted. CAUTION DO NOT REMOVE PLUGS WHEN THE ENGINE IS WARM OR HOT. THE ENGINE MUST BE AT ROOM TEMPERATURE WHEN PERFORMING SPARK PLUG SERVICE. REMOVING THE SPARK PLUGS FROM A WARM/HOT ENGINE INCREASES THE CHANCE THE THREADS COULD BE DAMAGED. Spark Plug Removal Procedure 1. Remove the coil-on-plug assemblies and thoroughly blow out the spark plug wells and surrounding valve cover area with compressed air. 2. Back out the spark plugs no more than 1/8 to 1/4 of a turn. Using Motorcraft(R) Carburetor Tune-Up Cleaner, fill the spark plug well just above where the jamb nut hex sits (1/2 - 3/4 teaspoon). A minimum period of 15 minutes of soak time is required. The cleaner will wick down to the ground electrode shield and soften the carbon deposits in this time. DO NOT WORK the spark plug back and forth at this point. NOTE COMPLETELY REVIEW THE PRODUCT LABEL FOR THE MOTORCRAFT CARBURETOR TUNE-UP CLEANER PRODUCT - USE AT ROOM TEMPERATURE AND SHAKE WELL. CAUTION EXCESSIVE MOTORCRAFT(R) CARBURETOR TUNE-UP CLEANER, OR REPEATING THE PROCESS SEVERAL TIMES WITH TOO MUCH CLEANER FLUID, COULD INTRODUCE ENOUGH LIQUID VOLUME TO HYDRO-LOCK THE ENGINE. CAUTION DO NOT USE AIR OR POWER TOOLS FOR SPARK PLUG REMOVAL. SPARK PLUGS MUST ONLY BE REMOVED WITH HAND TOOLS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 5046 3. Tighten, and then loosen the spark plug, working the plug back and forth. Some screeching and high effort may be noticed. The expected removal torque is about 33 lb-ft (45 N.m). Repeat the back and forth turning as needed until turning effort is reduced, and remove the spark plugs. NOTE NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT HIGH TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD. DO NOT COAT THE ELECTRODE STRAP. (Figure 1) Separated/Broken Spark Plug Removal If the spark plug separates after following the Spark Plug Removal Procedure, it will fail in one of three modes. Refer to the appropriate removal procedure as required. a. Mode 1: The ground electrode shield is left behind as an empty shell. (Figure 2) b. Mode 2: The entire porcelain insulator and ground electrode shield remains in the cylinder head. (Figure 3) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 5047 c. Mode 3: The upper section of porcelain broke off with remaining porcelain left inside the ground shield. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 5048 Flowchart of procedure. (Figure 5) Mode 1 Procedure: Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 5049 Use Rotunda special service tool 303-1203 to remove an empty ground electrode shield from the cylinder head. (Figure 6) NOTE THIS TOOL IS ONLY DESIGNED TO WORK WITH AN EMPTY GROUND ELECTRODE SHIELD. IF PORCELAIN REMAINS, PROCEED TO MODE 2 OR 3 REMOVAL. 1. Modify vacuum cap to a 3/8" (10 mm) length for each ground electrode shield that needs to be removed. (Figure 7) 2. Use the installation rod (J) provided with service tool 303-1203 update to install the modified vacuum cap. Push the cap into the ground shield down to the electrode strap. This will plug and protect the combustion chamber from contamination. (Figure 7) 3. Thread-tap the ground electrode shield using a 9.0 x 1.0 mm plug tap (tap profile is about 3-4 reduced diameter threads on the tip end). a. Coat the end of the tap with general purpose grease. (Figure 8) b. Turn the tap about 3 to 4 turns into the ground electrode shield. Back the tap up frequently to break chips and avoid cut material from coiling-up in the spark plug well. A tap socket adaptor (K) is provided with service tool 303-1203 update to connect the tap to a 3/8" socket Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 5050 drive. CAUTION DO NOT ATTEMPT TO REMOVE THE GROUND ELECTRODE SHIELD WITH THE TAP AND WRENCH. THE TAP MAY BREAK IF THIS IS ATTEMPTED. 4. Thread Rotunda special service tool 303-1203 into the ground electrode shield. (Figure 9) a. Install the stepped end of the tool pilot bushing into the spark plug well ensuring it bottoms out. b. Screw the center shank into the ground electrode shield. Do not over tighten the shank, to prevent thread stripping. c. Install the nylon washer and jack nut until finger tight. d. Turn the jack nut until the ground electrode is freed from the cavity and withdraw the tool assembly. NOTE NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD. DO NOT COAT THE ELECTRODE STRAP. Mode 2 Procedure: 1. Add an additional 1/2 teaspoon Motorcraft® Carburetor Tune-Up Cleaner fluid into spark plug well and allow 15 minutes of soak time. 2. Using long-reach nose pliers grasp and remove the porcelain with an up and down motion taking care not to fracture the porcelain. 3. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder head. Mode 3 Procedure: CAUTION DO NOT DRIVE PORCELAIN DOWN INTO THE GROUND SHIELD WITH A PUNCH AS FRAGMENTS MAY ENTER THE COMBUSTION CHAMBER. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 5051 Use Rotunda special service tool kit 303-1398 to remove porcelain broken inside the ground electrode shield. (FIGURE 10) Porcelain Removal - Preparation CAUTION THE ENGINE AND THE BONDING ADHESIVE MUST BE ROOM TEMPERATURE OF 70 °F (21 °C) OR HIGHER FOR PROPER CURE AND BOND STRENGTH. VERIFY EXPIRATION DATE OF ADHESIVE. CAUTION DO NOT REUSE PINS. THIS ENSURES THE CORRECT SURFACE CHARACTERISTICS FOR BONDING. 1. Remove any remaining electrode material from broken porcelain with long nose reach pliers. 2. Spray Motorcraft® Metal Brake Parts Cleaner into the porcelain hole for 2-4 seconds using the straw nozzle supplied with the brake cleaner can. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 5052 3. Insert a pin (A) into the collet (B). Screw the collet onto the threaded rod (C). Install the assembled collet, pin, and threaded rod into the steel tool pilot (F). (Figures 11 and 12) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 5053 4. Retract the collet and pin into the steel tool pilot, protecting the pin. (Figures 13 and 14) NOTE PIN TIP DAMAGE OR BENT PINS WILL PREVENT INSERTION INTO THE PORCELAIN. 5. Insert the completed assembly into the spark plug well and fully engage the pin into the porcelain. (Figure 15) 6. Spray Motorcraft(R) Metal Brake Parts Cleaner 2-4 seconds between the spark plug well and steel tool pilot. The steel tool pilot must be lifted up approximately 1/2" to allow brake cleaner to flood the porcelain and pin. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 5054 7. Scrub the porcelain inside diameter by moving the threaded rod up and down vigorously. Take care making sure the pin does not disengage the porcelain. (Figure 16). 8. Repeat Steps 6 and 7. 9. Remove the tool assembly. Again flood the porcelain with Motorcraft(R) Metal Brake Parts Cleaner for 2-4 seconds, then blow out the entire spark plug well and porcelain with dry compressed air. NOTE CLEAN AND DRY COMPONENTS ARE KEY TO BONDING THE PIN TO THE PORCELAIN. 10. Repeat Steps 1-9 to prepare remaining porcelain fragments as needed. 11. Disassemble the collet and pin from the threaded rod. Dry the tools thoroughly with dry compressed air. Porcelain Removal - Bonding Process CAUTION USE CARE TO PREVENT BONDING AGENT FROM CONTACTING THREADS IN CYLINDER HEAD. NOTE WORKING TIME LIMIT OF LOCTITE(R) 638(TM) RETAINING COMPOUND IS 5 MINUTES. 1. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to opposite sides of a clean and dry applicator (H). Excessive amounts of Loctite(R) 638(TM) are being used if it drips off the applicator. (Figure 17) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 5055 2. Insert applicator into the porcelain and move applicator up and down 1/2" (13 mm) while turning to spread the Loctite® 638TM on the inside of the porcelain. (Figure 18). 3. Add additional Loctite(R) 638(TM), repeating Steps 1 and 2. 4. Clean the applicator with Motorcraft(R) Metal Brake Parts Cleaner before the bonding agent starts to cure. 5. Reassemble a dry and clean collet and pin assembly. 6. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to the pin. Excessive amounts of Loctite® 638TMare being used if it drips off the pin. 7. Retract the collet and pin into the steel tool pilot to protect the Loctite(R) 638(TM) coated pin. 8. Insert the completed assembly into spark plug well and fully engage the pin into the porcelain with a twisting motion to spread the bonding agent. 9. Add additional Loctite® 638TM, repeating Steps 6-8. 10. Leave the pin fully inserted in the porcelain while the adhesive cures. Replace the steel tool pilot with the aluminum alignment sleeve (G), Figure 9, to support the threaded rod while the adhesive cures if additional porcelain fragments are present in other cylinders. (Figure 19). CAUTION A MINIMUM 1 HOUR CURING TIME AT 70 °F (21 °C) DEGREES IS REQUIRED BEFORE EXTRACTION IS ATTEMPTED. 11. Allow the Loctite(R) 638(TM) to cure for a minimum of one hour at 70 °F (21 °C). 12. Repeat the bonding process for remaining cylinders as needed. Porcelain Removal - Extraction 1. After a minimum of one hour curing at 70 °F (21 °C), install the steel pilot tool over the threaded rod. 2. Install the washer and jack nut until finger tight against the tool pilot bushing. CAUTION ONLY THE STEEL PILOT TOOL IS ACCEPTABLE FOR USE IN PORCELAIN REMOVAL. 3. While holding the end of the threaded rod with a wrench, tighten the jack nut until the porcelain is free of the ground electrode. 4. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder head. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 5056 NOTE NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD. DO NOT COAT THE ELECTRODE STRAP. (FIGURE 7) Porcelain Removal - Pin Slipped Out In the unlikely event that the pin does not remove the broken porcelain, this process can be repeated. Key elements to success are: ^ Clean and dry porcelain ^ Sufficient Loctite® 638TM Retaining Compound spread uniformly ^ Loctite(R) 638(TM) cure time and temperature ^ Preventing the threaded rod from rotating while removing the porcelain Replacement Supplies Replacement kit components and additional kit consumables (Loctite(R) 638TM Retaining Compound and pins) can be obtained by calling 1-800-ROTUNDA, Option 5. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT080706 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 12405 01 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark Plug Gap Spark Plug Gap ............................................................................................................................................................. 0.040 - 0.050 inch (1.02 - 1.27 mm) NOTE: Spark plug gap not adjustable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 5059 Spark Plug: Specifications Spark Plug Torque Spark Plugs ......................................................................................................................................... ................................................... 34 Nm (25.0 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 5060 Spark Plug: Application and ID Spark Plug ........................................................................................................................................... ...................................................................... PZT-2F Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 5061 Spark Plug: Service and Repair SPARK PLUGS Engine Ignition - RH Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 5062 Engine Ignition - LH Exploded View Removal and Installation 1. Remove the ignition coil-on-plug. 2. NOTE: - Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs. - If an original spark plug is used, make sure it is installed in the same cylinder from which it was taken. New spark plugs can be used in any cylinder. Remove the spark plugs. To install, tighten to 34 Nm (25 lb-ft). 3. Inspect the spark plugs. Install new spark plugs as necessary. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Pressure Regulating Solenoid: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5070 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5071 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5072 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5073 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5074 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5075 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5076 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5077 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5078 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5079 Pressure Regulating Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5080 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5081 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5082 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5083 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5084 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5085 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5086 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5087 Solenoid Operation Chart Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5088 Pressure Regulating Solenoid: Testing and Inspection 4R70E/4R75E Automatic Transmission Pinpoint Tests - OSC Equipped Vehicles Special Tools Any time an electrical connector or solenoid body is disconnected, inspect the connector for pin condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install a new connector or component as required. Shift Solenoids Pre-Diagnosis Use the following shift solenoid operation information when carrying out Pinpoint Test A. See: Testing and Inspection/Pinpoint Tests/Pinpoint Tests/Test A: Shift and Torque Converter Clutch Solenoids Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5089 Solenoid Operation Chart Shift Solenoid Failure Mode Chart "Always off" (Part 1) Shift Solenoid Failure Mode Chart "Always off" (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5090 Shift Solenoid Failure Mode Chart "Always off" (Part 3) Failed off due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck off. Shift Solenoid Failure Mode Chart "Always On" (Part 1) Shift Solenoid Failure Mode Chart "Always On" (Part 2) Shift Solenoid Failure Mode Chart "Always On" (Part 3) Failed on due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck on. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5091 Pressure Regulating Solenoid: Service and Repair 4R70E/4R75E Electronic Pressure Control (EPC) Solenoid Special Tools Removal CAUTION: Do not pull on the molded 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. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid and remove the transmission fluid pan and filter. 3. 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 interconnector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5092 4. Remove the EPC solenoid. Installation 1. NOTE: Lubricate the EPC solenoid O-rings with clean automatic transmission fluid. Install the EPC solenoid, bracket and bolt. ^ Tighten to 10 Nm (89 inch lbs.). 2. Inspect the lead frame for damage. ^ Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted. ^ If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, ^ Install a new lead frame. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5093 3. Connect the molded lead frame to the solenoids. 1 Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 2 Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 3 Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 4 Connect the bulkhead interconnector by pressing it in place by hand and fully seating the connector in place. 4. Install the transmission fluid pan and filter. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator Column Shift Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Column Shift Brake Shift Interlock Actuator Column Shift Brake Shift Interlock Actuator - Column Shift Removal and Installation 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 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 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator Column Shift > Page 5098 latches. Please refer to the appropriate vehicle shop manual to determine 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). Disconnect the battery ground cable. Wait at least one minute before proceeding with the procedure to allow the backup power supply to deplete its energy. 2. Remove the supplemental restraint system (SRS) steering column clockspring. 3. Remove the 3 bolts and remove the clockspring mounting bracket from the steering column. ^ To install, tighten to 6 Nm (53 inch lbs.). 4. Remove the 3 screws and position the wiring harnesses aside. 5. Disconnect the interlock actuator electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator Column Shift > Page 5099 6. Remove the 2 screws and position the actuator aside. 7. Remove the 2 bolts and position the selector lever detent bracket aside. ^ To install, tighten to 6 Nm (53 inch lbs.). 8. Remove the shift lock actuator from the detent bracket and remove the shift lock actuator. 9. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator Column Shift > Page 5100 Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Floor Shift Brake Shift Interlock Actuator Floor Shift Removal and Installation NOTE: The brake shift interlock actuator is not serviced individually. If replacement is required, install a new floor shift selector lever assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5105 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5106 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5107 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5108 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5109 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5110 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5111 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5112 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5113 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5114 Shift Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5115 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5116 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5117 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5118 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5119 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5120 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5121 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5122 Solenoid Operation Chart Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5123 Shift Solenoid: Testing and Inspection 4R70E/4R75E Automatic Transmission Pinpoint Tests - OSC Equipped Vehicles Special Tools Any time an electrical connector or solenoid body is disconnected, inspect the connector for pin condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install a new connector or component as required. Shift Solenoids Pre-Diagnosis Use the following shift solenoid operation information when carrying out Pinpoint Test A. See: Testing and Inspection/Pinpoint Tests/Pinpoint Tests/Test A: Shift and Torque Converter Clutch Solenoids Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5124 Solenoid Operation Chart Shift Solenoid Failure Mode Chart "Always off" (Part 1) Shift Solenoid Failure Mode Chart "Always off" (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5125 Shift Solenoid Failure Mode Chart "Always off" (Part 3) Failed off due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck off. Shift Solenoid Failure Mode Chart "Always On" (Part 1) Shift Solenoid Failure Mode Chart "Always On" (Part 2) Shift Solenoid Failure Mode Chart "Always On" (Part 3) Failed on due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck on. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5126 Shift Solenoid: Service and Repair 4R70E/4R75E Electronic Pressure Control (EPC) Solenoid Special Tools Removal CAUTION: Do not pull on the molded 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. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid and remove the transmission fluid pan and filter. 3. 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 interconnector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5127 4. Remove the EPC solenoid. Installation 1. NOTE: Lubricate the EPC solenoid O-rings with clean automatic transmission fluid. Install the EPC solenoid, bracket and bolt. ^ Tighten to 10 Nm (89 inch lbs.). 2. Inspect the lead frame for damage. ^ Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted. ^ If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, ^ Install a new lead frame. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5128 3. Connect the molded lead frame to the solenoids. 1 Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 2 Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 3 Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 4 Connect the bulkhead interconnector by pressing it in place by hand and fully seating the connector in place. 4. Install the transmission fluid pan and filter. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5133 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5134 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5135 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5136 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5137 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5138 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5139 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5140 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5141 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5142 Torque Converter Clutch Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5143 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5144 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5145 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5146 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5147 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5148 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5149 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5150 Solenoid Operation Chart Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5151 Torque Converter Clutch Solenoid: Testing and Inspection 4R70E/4R75E Automatic Transmission Pinpoint Tests - OSC Equipped Vehicles Special Tools Any time an electrical connector or solenoid body is disconnected, inspect the connector for pin condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install a new connector or component as required. Shift Solenoids Pre-Diagnosis Use the following shift solenoid operation information when carrying out Pinpoint Test A. See: Testing and Inspection/Pinpoint Tests/Pinpoint Tests/Test A: Shift and Torque Converter Clutch Solenoids Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5152 Solenoid Operation Chart Shift Solenoid Failure Mode Chart "Always off" (Part 1) Shift Solenoid Failure Mode Chart "Always off" (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5153 Shift Solenoid Failure Mode Chart "Always off" (Part 3) Failed off due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck off. Shift Solenoid Failure Mode Chart "Always On" (Part 1) Shift Solenoid Failure Mode Chart "Always On" (Part 2) Shift Solenoid Failure Mode Chart "Always On" (Part 3) Failed on due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck on. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5154 Torque Converter Clutch Solenoid: Service and Repair 4R70E/4R75E Electronic Pressure Control (EPC) Solenoid Special Tools Removal CAUTION: Do not pull on the molded 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. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid and remove the transmission fluid pan and filter. 3. 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 interconnector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5155 4. Remove the EPC solenoid. Installation 1. NOTE: Lubricate the EPC solenoid O-rings with clean automatic transmission fluid. Install the EPC solenoid, bracket and bolt. ^ Tighten to 10 Nm (89 inch lbs.). 2. Inspect the lead frame for damage. ^ Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted. ^ If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, ^ Install a new lead frame. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5156 3. Connect the molded lead frame to the solenoids. 1 Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 2 Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 3 Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 4 Connect the bulkhead interconnector by pressing it in place by hand and fully seating the connector in place. 4. Install the transmission fluid pan and filter. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation TRANSMISSION CONTROL INDICATOR LAMP (TCIL) The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 > Service and Repair Control Module: Service and Repair Four-Wheel Drive (4WD) Control Module Removal and Installation NOTE: The Four Wheel Drive (4WD) control module is integral to the Powertrain Control Module (PCM) and is not serviced separately. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 Four Wheel Drive Selector Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 5170 View 151-1 (Engine Compartment) The transfercase Low to High and High to Low relays are located in the Auxiliary relay box 1 located in the engine compartment. LH side, front. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 > Diagrams > Transfer Case Low to High Relay C1129 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 > Diagrams > Transfer Case Low to High Relay > Page 5173 C1173 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 > Testing and Inspection > Transfer Case Low to High Relay Four Wheel Drive Selector Relay: Testing and Inspection Transfer Case Low to High Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 > Testing and Inspection > Transfer Case Low to High Relay > Page 5176 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 > Testing and Inspection > Transfer Case Low to High Relay > Page 5177 Four Wheel Drive Selector Relay: Testing and Inspection Transfer Case High to Low Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 > Testing and Inspection > Transfer Case Low to High Relay > Page 5178 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions Brake Switch - TCC: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5185 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5186 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5187 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5188 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5189 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5190 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5191 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5192 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5193 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5194 Brake Switch - TCC: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5195 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5196 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5197 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5198 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5199 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5200 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5201 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Page 5202 Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - BPP switch is hardwired to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - BPP switch is hardwired to the Anti-Lock Brake System (ABS) Module, Lighting Control Module (LCM), or Rear Electronic Module (REM), the BPP signal is then broadcast over the network to be received by the PCM. - BPP switch is hardwired to the anti-lock brake system (ABS) traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations View 151-14 (Steering Column) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Overdrive Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5208 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5209 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5210 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5211 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5212 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5213 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5214 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5215 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5216 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5217 Overdrive Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5218 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5219 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5220 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5221 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5222 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5223 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5224 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5225 C2135 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor/Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5230 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5231 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5232 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5233 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5234 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5235 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5236 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5237 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5238 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5239 Throttle Position Sensor/Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5240 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5241 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5242 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5243 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5244 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5245 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5246 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Mode Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5251 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5252 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5253 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5254 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5255 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5256 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5257 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5258 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5259 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5260 Transmission Mode Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5261 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5262 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5263 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5264 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5265 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5266 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5267 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 5268 Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH (TCS) Typical Transmission Control Switch (TCS) Typical Transmission Control Switch (TCS) The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature, the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage overdrive. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5272 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5275 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5276 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5277 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5278 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5279 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5280 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5281 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5282 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5283 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5284 Transmission Position Switch/Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5285 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5286 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5287 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5288 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5289 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5290 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5291 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5292 C167 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5293 Transmission Position Switch/Sensor: Adjustments 4R70E/4R75E Transmission Range (TR) Sensor Adjustment Special Tools 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual lever shift control cable. 3. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control lever nut. 2 Remove the manual control lever. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5294 4. Loosen the digital transmission range (TR) sensor bolts. 5. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 6. CAUTION: Tightening one bolt before tightening the other may cause the sensor to bind or become damaged. Using the special tool, align the digital TR sensor and tighten the bolts in an alternating sequence. ^ Tighten to 9 Nm (80 inch lbs.). 7. Install the manual control lever. ^ Position the manual control lever. 2 Install a new manual lever shaft outer nut. ^ Tighten to 33 Nm (24 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5295 8. With the manual lever in overdrive connect the shift lever control cable. 9. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5296 Transmission Position Switch/Sensor: Service and Repair 4R70E/4R75E Automatic Transmission Digital Transmission Range (TR) Sensor Special Tools Removal NOTE: Manual shift lever must be in the NEUTRAL position. 1. With the vehicle in NEUTRAL, position it on a hoist. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5297 2. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual control lever shift control cable. 3. Disconnect the digital TR electrical connector. 4. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control nut. 2 Remove the manual control lever. 5. Remove the digital TR sensor bolts and the digital TR sensor. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5298 1. Install the digital TR sensor and loosely install the bolts. 2. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 3. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. Tighten the digital TR sensor bolts. ^ Tighten to 9 Nm (80 inch lbs.). 4. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual control lever nut. ^ Tighten to 33 Nm (24 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5299 5. Connect the digital TR sensor electrical connector. 6. Connect the shift cable end to the manual lever with the lever in the (D) position. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Turbine Shaft Speed (TSS) Sensor > Page 5304 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Turbine Shaft Speed (TSS) Sensor > Page 5305 Transmission Speed Sensor: Locations Output Shaft Speed (OSS) Sensor View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Turbine Shaft Speed (TSS) Sensor > Page 5306 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Speed Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5309 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5310 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5311 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5312 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5313 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5314 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5315 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5316 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5317 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5318 Transmission Speed Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5319 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5320 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5321 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5322 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5323 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5324 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5325 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5326 Transmission Speed Sensor: Connector Views C193 C143 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5327 Transmission Speed Sensor: Service and Repair 4R70E/4R75E Automatic Transmission Speed Sensors Speed Sensors NOTE: Only remove the affected sensor. Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist, OSS sensor 2. Disconnect the output shaft speed (OSS) sensor electrical connector. 3. Remove the OSS sensor bolt. 4. Remove the OSS sensor. TSS sensor 5. Disconnect the turbine shaft speed (TSS) sensor electrical connector. 6. Remove the TSS sensor bolt. 7. Remove the TSS sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5328 Installation TSS sensor 1. Lubricate the O-ring seal and install the TSS sensor. 2. Install the TSS sensor bolt. ^ Tighten to 11 Nm (8 ft. lbs.). 3. Connect the TSS sensor electrical connector. OSS sensor 4. Lubricate the O-ring seal and install the OSS sensor. 5. Install the OSS sensor bolt. ^ Tighten to 12 Nm (9 ft. lbs.). 6. Connect the OSS sensor electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations View 151-12 (Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 5333 C284 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 06-13-9 > Jul > 06 > Engine Controls - Hard Start/MIL ON/Multiple DTC's Set PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Hard Start/MIL ON/Multiple DTC's Set TSB 06-13-9 07/10/06 HARD START, LOW POWER AT 3500 RPM, MIL ON P0340, P0344, P0172, P0175 AND EXPEDITION ONLY - IDLES TOO FAST COLD FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-4-15 to update the vehicle model years. ISSUE Some 2005-2006 Expedition/Navigators may exhibit a hard start during multiple restart attempts or during hot soak restart attempts and / or the malfunction indicator lamp (MIL) on with diagnostic trouble codes (DTCs) P0340, P0344, P0172, and / or P0175 and / or a reduction in power between 3500 and 4500 RPM during wide open throttle (WOT) application. Some customers may describe the condition as feeling like the transmission is slipping, a lack of transmission upshift or a hesitation. 2005-2006 Expedition (only) may also exhibit a higher than normal idle on cold start. ACTION Follow normal diagnostics for the vehicle symptom(s) to determine if there is an actual physical issue with the fuel / ignition / exhaust systems and / or base engine causing the symptom(s). If no issues are found during normal diagnostics and the symptoms still occur, reprogram the powertrain control module (PCM) to the latest calibration using IDS Release B43.4 or later. Calibration files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 061309A 2005-2006 0.4 Hr. Expedition/Navigator 5.4L 3V: Check Diagnostic Trouble Codes And Reprogram The Powertrain Control Module (Do Not Use With 12650D, 12650D84) MT061309 Claim Additional Labor Actual Required As Actual Time Time Or Use SLTS Operation If Available DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 06-5-1 > Mar > 06 > Engine Controls - Cold Start Rough Idle Condition PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Cold Start Rough Idle Condition TSB 06-5-1 03/20/06 COLD START ROUGH IDLE EXPEDITION 4X2 ONLY FORD: 2005-2006 Expedition ISSUE Some 2005-2006 Expedition 4x2 vehicles may exhibit an idle vibration during cold start at 1400 RPM, that lasts for a few seconds. The symptom is perceived as shaking of the entire vehicle when the engine is first started after being off for an extended period of time in warm weather in excess of a few hours, such as overnight, with ambient temperatures greater than 60° F (16° C). The issue is not typically accompanied by unusual engine or fan noise. It is independent of air conditioning compressor engagement (bumps, bangs, or thumps) and air suspension pump operation (audible hum or buzz accompanied by an associated vibration). ACTION Use the following Service Procedure to resolve the concern. SERVICE PROCEDURE 1. Using normal Workshop Manual diagnostics: a. Verify the integrity of the fuel system (fuel injectors, fuel pump, fuel quality) and repair as necessary. b. Check ignition system (spark plugs, ignition coils), mechanical engine operation, and repair as necessary. 2. Check the engine assembly exhaust mounting systems for ground-outs, damage, and repair as necessary. 3. If no concerns are found or cold start symptoms continue, reprogram the powertrain control module (PCM) to the latest calibration using WDS release B41.10 and higher or B42.1 and higher. This new calibration is not included in the B42 CD. Calibration files may also be obtained at the website. NOTE COLD ENGINE IDLE SPEED WILL DROP TO 1250 RPM AND WARM DRIVE IDLE SPEED WILL INCREASE TO 650 RPM. THIS CALIBRATION IS MATCHED TO THE SERVICE ENGINE/TRANSMISSION MOUNTS LISTED IN THIS TSB. DO NOT RE-INSTALL THE ORIGINAL ENGINE/TRANSMISSION MOUNTS AFTER PERFORMING THIS RECALIBRATION. 4. Replace the left hand and right hand engine mounts. Refer to the Workshop Manual, Section 303-01 - Engine Support Insulators 5. Replace the transmission mount. Refer to Workshop Manual, Section 307-01B - Transmission Insulator & Retainer Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 060501A 2005 Expedition 4X2: 3.7 Hrs. Replace Both Engine Mounts, and Transmission Mount, Reprogram The Powertrain Control Module (Do Not Use With 6038A, 6068A, 12650D, 12650D84, 050415A, Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 06-5-1 > Mar > 06 > Engine Controls - Cold Start Rough Idle Condition > Page 5346 052301A) 060501B 2006 Expedition 4X2: 3.6 Hrs. Replace Both Engine Mounts, and Transmission Mount, Reprogram The Powertrain Control Module (Do Not Use With 6038A, 6068A, 12650D, 12650D84, 050415A, 052301A) MT060501 Claim Additional Labor Actual Required As Actual Time Time Or Use SLTS Operation If Available DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 05-23-1 > Nov > 05 > Engine Controls - MIL ON/DTC P0351-P0358/Delayed Shifts PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC P0351-P0358/Delayed Shifts TSB 05-23-1 11/28/05 MIL ON WITH DTC P0351-P0358 - LACK OF UPSHIFT FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-21-15 to update the vehicle model years. ISSUE Some 2005-2006 Expedition vehicles built before 9/29/2005 and Navigator vehicles built before 10/19/2005 may exhibit any/all of the following symptoms: ^ Malfunction indicator lamp on (MIL) with diagnostic trouble codes (DTCs) P0351-P0358 and no drivability symptoms ^ (Navigator only) Delayed 1-2 shifts or lack of upshift, especially at low speeds with no DTCs. This condition may be due to the driver resting his/her foot on the brake pedal while accelerating ACTION Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B39.9 and higher or B40.1 and higher. This new calibration is not included in the B40 CD. Calibration files may also be obtained at the website. NOTE DO NOT PERFORM THIS TSB FOR DTC P0351-0358 IF DRIVEABILITY SYMPTOMS ARE PRESENT. FOLLOW NORMAL DIAGNOSTICS INSTEAD. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 052301A 2005-2006 0.4 Hr Expedition/Navigator: Check For Diagnostic Trouble Codes And Reprogram The Powertrain Control Module (Do Not Use With 12650D, 12650D84) DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 06-13-9 > Jul > 06 > Engine Controls - Hard Start/MIL ON/Multiple DTC's Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - Hard Start/MIL ON/Multiple DTC's Set TSB 06-13-9 07/10/06 HARD START, LOW POWER AT 3500 RPM, MIL ON P0340, P0344, P0172, P0175 AND EXPEDITION ONLY - IDLES TOO FAST COLD FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-4-15 to update the vehicle model years. ISSUE Some 2005-2006 Expedition/Navigators may exhibit a hard start during multiple restart attempts or during hot soak restart attempts and / or the malfunction indicator lamp (MIL) on with diagnostic trouble codes (DTCs) P0340, P0344, P0172, and / or P0175 and / or a reduction in power between 3500 and 4500 RPM during wide open throttle (WOT) application. Some customers may describe the condition as feeling like the transmission is slipping, a lack of transmission upshift or a hesitation. 2005-2006 Expedition (only) may also exhibit a higher than normal idle on cold start. ACTION Follow normal diagnostics for the vehicle symptom(s) to determine if there is an actual physical issue with the fuel / ignition / exhaust systems and / or base engine causing the symptom(s). If no issues are found during normal diagnostics and the symptoms still occur, reprogram the powertrain control module (PCM) to the latest calibration using IDS Release B43.4 or later. Calibration files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 061309A 2005-2006 0.4 Hr. Expedition/Navigator 5.4L 3V: Check Diagnostic Trouble Codes And Reprogram The Powertrain Control Module (Do Not Use With 12650D, 12650D84) MT061309 Claim Additional Labor Actual Required As Actual Time Time Or Use SLTS Operation If Available DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 06-5-1 > Mar > 06 > Engine Controls - Cold Start Rough Idle Condition PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - Cold Start Rough Idle Condition TSB 06-5-1 03/20/06 COLD START ROUGH IDLE EXPEDITION 4X2 ONLY FORD: 2005-2006 Expedition ISSUE Some 2005-2006 Expedition 4x2 vehicles may exhibit an idle vibration during cold start at 1400 RPM, that lasts for a few seconds. The symptom is perceived as shaking of the entire vehicle when the engine is first started after being off for an extended period of time in warm weather in excess of a few hours, such as overnight, with ambient temperatures greater than 60° F (16° C). The issue is not typically accompanied by unusual engine or fan noise. It is independent of air conditioning compressor engagement (bumps, bangs, or thumps) and air suspension pump operation (audible hum or buzz accompanied by an associated vibration). ACTION Use the following Service Procedure to resolve the concern. SERVICE PROCEDURE 1. Using normal Workshop Manual diagnostics: a. Verify the integrity of the fuel system (fuel injectors, fuel pump, fuel quality) and repair as necessary. b. Check ignition system (spark plugs, ignition coils), mechanical engine operation, and repair as necessary. 2. Check the engine assembly exhaust mounting systems for ground-outs, damage, and repair as necessary. 3. If no concerns are found or cold start symptoms continue, reprogram the powertrain control module (PCM) to the latest calibration using WDS release B41.10 and higher or B42.1 and higher. This new calibration is not included in the B42 CD. Calibration files may also be obtained at the website. NOTE COLD ENGINE IDLE SPEED WILL DROP TO 1250 RPM AND WARM DRIVE IDLE SPEED WILL INCREASE TO 650 RPM. THIS CALIBRATION IS MATCHED TO THE SERVICE ENGINE/TRANSMISSION MOUNTS LISTED IN THIS TSB. DO NOT RE-INSTALL THE ORIGINAL ENGINE/TRANSMISSION MOUNTS AFTER PERFORMING THIS RECALIBRATION. 4. Replace the left hand and right hand engine mounts. Refer to the Workshop Manual, Section 303-01 - Engine Support Insulators 5. Replace the transmission mount. Refer to Workshop Manual, Section 307-01B - Transmission Insulator & Retainer Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 060501A 2005 Expedition 4X2: 3.7 Hrs. Replace Both Engine Mounts, and Transmission Mount, Reprogram The Powertrain Control Module (Do Not Use With 6038A, 6068A, 12650D, 12650D84, 050415A, Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 06-5-1 > Mar > 06 > Engine Controls - Cold Start Rough Idle Condition > Page 5360 052301A) 060501B 2006 Expedition 4X2: 3.6 Hrs. Replace Both Engine Mounts, and Transmission Mount, Reprogram The Powertrain Control Module (Do Not Use With 6038A, 6068A, 12650D, 12650D84, 050415A, 052301A) MT060501 Claim Additional Labor Actual Required As Actual Time Time Or Use SLTS Operation If Available DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 05-23-1 > Nov > 05 > Engine Controls - MIL ON/DTC P0351-P0358/Delayed Shifts PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0351-P0358/Delayed Shifts TSB 05-23-1 11/28/05 MIL ON WITH DTC P0351-P0358 - LACK OF UPSHIFT FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-21-15 to update the vehicle model years. ISSUE Some 2005-2006 Expedition vehicles built before 9/29/2005 and Navigator vehicles built before 10/19/2005 may exhibit any/all of the following symptoms: ^ Malfunction indicator lamp on (MIL) with diagnostic trouble codes (DTCs) P0351-P0358 and no drivability symptoms ^ (Navigator only) Delayed 1-2 shifts or lack of upshift, especially at low speeds with no DTCs. This condition may be due to the driver resting his/her foot on the brake pedal while accelerating ACTION Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B39.9 and higher or B40.1 and higher. This new calibration is not included in the B40 CD. Calibration files may also be obtained at the website. NOTE DO NOT PERFORM THIS TSB FOR DTC P0351-0358 IF DRIVEABILITY SYMPTOMS ARE PRESENT. FOLLOW NORMAL DIAGNOSTICS INSTEAD. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 052301A 2005-2006 0.4 Hr Expedition/Navigator: Check For Diagnostic Trouble Codes And Reprogram The Powertrain Control Module (Do Not Use With 12650D, 12650D84) DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Pressure Regulating Solenoid: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5372 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5373 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5374 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5375 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5376 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5377 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5378 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5379 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5380 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5381 Pressure Regulating Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5382 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5383 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5384 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5385 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5386 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5387 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5388 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5389 Solenoid Operation Chart Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5390 Pressure Regulating Solenoid: Testing and Inspection 4R70E/4R75E Automatic Transmission Pinpoint Tests - OSC Equipped Vehicles Special Tools Any time an electrical connector or solenoid body is disconnected, inspect the connector for pin condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install a new connector or component as required. Shift Solenoids Pre-Diagnosis Use the following shift solenoid operation information when carrying out Pinpoint Test A. See: Transmission Control Systems/Testing and Inspection/Pinpoint Tests/Pinpoint Tests/Test A: Shift and Torque Converter Clutch Solenoids Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5391 Solenoid Operation Chart Shift Solenoid Failure Mode Chart "Always off" (Part 1) Shift Solenoid Failure Mode Chart "Always off" (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5392 Shift Solenoid Failure Mode Chart "Always off" (Part 3) Failed off due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck off. Shift Solenoid Failure Mode Chart "Always On" (Part 1) Shift Solenoid Failure Mode Chart "Always On" (Part 2) Shift Solenoid Failure Mode Chart "Always On" (Part 3) Failed on due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck on. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5393 Pressure Regulating Solenoid: Service and Repair 4R70E/4R75E Electronic Pressure Control (EPC) Solenoid Special Tools Removal CAUTION: Do not pull on the molded 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. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid and remove the transmission fluid pan and filter. 3. 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 interconnector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5394 4. Remove the EPC solenoid. Installation 1. NOTE: Lubricate the EPC solenoid O-rings with clean automatic transmission fluid. Install the EPC solenoid, bracket and bolt. ^ Tighten to 10 Nm (89 inch lbs.). 2. Inspect the lead frame for damage. ^ Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted. ^ If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, ^ Install a new lead frame. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5395 3. Connect the molded lead frame to the solenoids. 1 Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 2 Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 3 Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 4 Connect the bulkhead interconnector by pressing it in place by hand and fully seating the connector in place. 4. Install the transmission fluid pan and filter. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator Column Shift Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Column Shift Brake Shift Interlock Actuator Column Shift Brake Shift Interlock Actuator - Column Shift Removal and Installation 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 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 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator Column Shift > Page 5400 latches. Please refer to the appropriate vehicle shop manual to determine 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). Disconnect the battery ground cable. Wait at least one minute before proceeding with the procedure to allow the backup power supply to deplete its energy. 2. Remove the supplemental restraint system (SRS) steering column clockspring. 3. Remove the 3 bolts and remove the clockspring mounting bracket from the steering column. ^ To install, tighten to 6 Nm (53 inch lbs.). 4. Remove the 3 screws and position the wiring harnesses aside. 5. Disconnect the interlock actuator electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator Column Shift > Page 5401 6. Remove the 2 screws and position the actuator aside. 7. Remove the 2 bolts and position the selector lever detent bracket aside. ^ To install, tighten to 6 Nm (53 inch lbs.). 8. Remove the shift lock actuator from the detent bracket and remove the shift lock actuator. 9. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator Column Shift > Page 5402 Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Floor Shift Brake Shift Interlock Actuator Floor Shift Removal and Installation NOTE: The brake shift interlock actuator is not serviced individually. If replacement is required, install a new floor shift selector lever assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5407 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5408 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5409 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5410 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5411 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5412 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5413 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5414 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5415 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5416 Shift Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5417 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5418 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5419 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5420 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5421 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5422 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5423 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5424 Solenoid Operation Chart Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5425 Shift Solenoid: Testing and Inspection 4R70E/4R75E Automatic Transmission Pinpoint Tests - OSC Equipped Vehicles Special Tools Any time an electrical connector or solenoid body is disconnected, inspect the connector for pin condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install a new connector or component as required. Shift Solenoids Pre-Diagnosis Use the following shift solenoid operation information when carrying out Pinpoint Test A. See: Transmission Control Systems/Testing and Inspection/Pinpoint Tests/Pinpoint Tests/Test A: Shift and Torque Converter Clutch Solenoids Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5426 Solenoid Operation Chart Shift Solenoid Failure Mode Chart "Always off" (Part 1) Shift Solenoid Failure Mode Chart "Always off" (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5427 Shift Solenoid Failure Mode Chart "Always off" (Part 3) Failed off due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck off. Shift Solenoid Failure Mode Chart "Always On" (Part 1) Shift Solenoid Failure Mode Chart "Always On" (Part 2) Shift Solenoid Failure Mode Chart "Always On" (Part 3) Failed on due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck on. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5428 Shift Solenoid: Service and Repair 4R70E/4R75E Electronic Pressure Control (EPC) Solenoid Special Tools Removal CAUTION: Do not pull on the molded 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. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid and remove the transmission fluid pan and filter. 3. 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 interconnector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5429 4. Remove the EPC solenoid. Installation 1. NOTE: Lubricate the EPC solenoid O-rings with clean automatic transmission fluid. Install the EPC solenoid, bracket and bolt. ^ Tighten to 10 Nm (89 inch lbs.). 2. Inspect the lead frame for damage. ^ Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted. ^ If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, ^ Install a new lead frame. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5430 3. Connect the molded lead frame to the solenoids. 1 Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 2 Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 3 Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 4 Connect the bulkhead interconnector by pressing it in place by hand and fully seating the connector in place. 4. Install the transmission fluid pan and filter. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5435 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5436 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5437 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5438 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5439 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5440 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5441 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5442 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5443 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5444 Torque Converter Clutch Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5445 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5446 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5447 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5448 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5449 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5450 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5451 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5452 Solenoid Operation Chart Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5453 Torque Converter Clutch Solenoid: Testing and Inspection 4R70E/4R75E Automatic Transmission Pinpoint Tests - OSC Equipped Vehicles Special Tools Any time an electrical connector or solenoid body is disconnected, inspect the connector for pin condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install a new connector or component as required. Shift Solenoids Pre-Diagnosis Use the following shift solenoid operation information when carrying out Pinpoint Test A. See: Transmission Control Systems/Testing and Inspection/Pinpoint Tests/Pinpoint Tests/Test A: Shift and Torque Converter Clutch Solenoids Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5454 Solenoid Operation Chart Shift Solenoid Failure Mode Chart "Always off" (Part 1) Shift Solenoid Failure Mode Chart "Always off" (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5455 Shift Solenoid Failure Mode Chart "Always off" (Part 3) Failed off due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck off. Shift Solenoid Failure Mode Chart "Always On" (Part 1) Shift Solenoid Failure Mode Chart "Always On" (Part 2) Shift Solenoid Failure Mode Chart "Always On" (Part 3) Failed on due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck on. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5456 Torque Converter Clutch Solenoid: Service and Repair 4R70E/4R75E Electronic Pressure Control (EPC) Solenoid Special Tools Removal CAUTION: Do not pull on the molded 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. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid and remove the transmission fluid pan and filter. 3. 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 interconnector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5457 4. Remove the EPC solenoid. Installation 1. NOTE: Lubricate the EPC solenoid O-rings with clean automatic transmission fluid. Install the EPC solenoid, bracket and bolt. ^ Tighten to 10 Nm (89 inch lbs.). 2. Inspect the lead frame for damage. ^ Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted. ^ If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, ^ Install a new lead frame. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5458 3. Connect the molded lead frame to the solenoids. 1 Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 2 Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 3 Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 4 Connect the bulkhead interconnector by pressing it in place by hand and fully seating the connector in place. 4. Install the transmission fluid pan and filter. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Pressure Regulating Solenoid: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5465 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5466 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5467 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5468 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5469 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5470 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5471 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5472 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5473 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5474 Pressure Regulating Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5475 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5476 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5477 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5478 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5479 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5480 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5481 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5482 Solenoid Operation Chart Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5483 Pressure Regulating Solenoid: Testing and Inspection 4R70E/4R75E Automatic Transmission Pinpoint Tests - OSC Equipped Vehicles Special Tools Any time an electrical connector or solenoid body is disconnected, inspect the connector for pin condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install a new connector or component as required. Shift Solenoids Pre-Diagnosis Use the following shift solenoid operation information when carrying out Pinpoint Test A. See: Transmission Control Systems/Testing and Inspection/Pinpoint Tests/Pinpoint Tests/Test A: Shift and Torque Converter Clutch Solenoids Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5484 Solenoid Operation Chart Shift Solenoid Failure Mode Chart "Always off" (Part 1) Shift Solenoid Failure Mode Chart "Always off" (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5485 Shift Solenoid Failure Mode Chart "Always off" (Part 3) Failed off due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck off. Shift Solenoid Failure Mode Chart "Always On" (Part 1) Shift Solenoid Failure Mode Chart "Always On" (Part 2) Shift Solenoid Failure Mode Chart "Always On" (Part 3) Failed on due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck on. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5486 Pressure Regulating Solenoid: Service and Repair 4R70E/4R75E Electronic Pressure Control (EPC) Solenoid Special Tools Removal CAUTION: Do not pull on the molded 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. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid and remove the transmission fluid pan and filter. 3. 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 interconnector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5487 4. Remove the EPC solenoid. Installation 1. NOTE: Lubricate the EPC solenoid O-rings with clean automatic transmission fluid. Install the EPC solenoid, bracket and bolt. ^ Tighten to 10 Nm (89 inch lbs.). 2. Inspect the lead frame for damage. ^ Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted. ^ If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, ^ Install a new lead frame. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5488 3. Connect the molded lead frame to the solenoids. 1 Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 2 Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 3 Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 4 Connect the bulkhead interconnector by pressing it in place by hand and fully seating the connector in place. 4. Install the transmission fluid pan and filter. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator Column Shift Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Column Shift Brake Shift Interlock Actuator Column Shift Brake Shift Interlock Actuator - Column Shift Removal and Installation 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 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 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator Column Shift > Page 5493 latches. Please refer to the appropriate vehicle shop manual to determine 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). Disconnect the battery ground cable. Wait at least one minute before proceeding with the procedure to allow the backup power supply to deplete its energy. 2. Remove the supplemental restraint system (SRS) steering column clockspring. 3. Remove the 3 bolts and remove the clockspring mounting bracket from the steering column. ^ To install, tighten to 6 Nm (53 inch lbs.). 4. Remove the 3 screws and position the wiring harnesses aside. 5. Disconnect the interlock actuator electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator Column Shift > Page 5494 6. Remove the 2 screws and position the actuator aside. 7. Remove the 2 bolts and position the selector lever detent bracket aside. ^ To install, tighten to 6 Nm (53 inch lbs.). 8. Remove the shift lock actuator from the detent bracket and remove the shift lock actuator. 9. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator Column Shift > Page 5495 Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Floor Shift Brake Shift Interlock Actuator Floor Shift Removal and Installation NOTE: The brake shift interlock actuator is not serviced individually. If replacement is required, install a new floor shift selector lever assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5500 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5501 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5502 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5503 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5504 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5505 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5506 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5507 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5508 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5509 Shift Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5510 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5511 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5512 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5513 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5514 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5515 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5516 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5517 Solenoid Operation Chart Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5518 Shift Solenoid: Testing and Inspection 4R70E/4R75E Automatic Transmission Pinpoint Tests - OSC Equipped Vehicles Special Tools Any time an electrical connector or solenoid body is disconnected, inspect the connector for pin condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install a new connector or component as required. Shift Solenoids Pre-Diagnosis Use the following shift solenoid operation information when carrying out Pinpoint Test A. See: Transmission Control Systems/Testing and Inspection/Pinpoint Tests/Pinpoint Tests/Test A: Shift and Torque Converter Clutch Solenoids Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5519 Solenoid Operation Chart Shift Solenoid Failure Mode Chart "Always off" (Part 1) Shift Solenoid Failure Mode Chart "Always off" (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5520 Shift Solenoid Failure Mode Chart "Always off" (Part 3) Failed off due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck off. Shift Solenoid Failure Mode Chart "Always On" (Part 1) Shift Solenoid Failure Mode Chart "Always On" (Part 2) Shift Solenoid Failure Mode Chart "Always On" (Part 3) Failed on due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck on. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5521 Shift Solenoid: Service and Repair 4R70E/4R75E Electronic Pressure Control (EPC) Solenoid Special Tools Removal CAUTION: Do not pull on the molded 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. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid and remove the transmission fluid pan and filter. 3. 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 interconnector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5522 4. Remove the EPC solenoid. Installation 1. NOTE: Lubricate the EPC solenoid O-rings with clean automatic transmission fluid. Install the EPC solenoid, bracket and bolt. ^ Tighten to 10 Nm (89 inch lbs.). 2. Inspect the lead frame for damage. ^ Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted. ^ If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, ^ Install a new lead frame. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5523 3. Connect the molded lead frame to the solenoids. 1 Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 2 Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 3 Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 4 Connect the bulkhead interconnector by pressing it in place by hand and fully seating the connector in place. 4. Install the transmission fluid pan and filter. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5528 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5529 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5530 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5531 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5532 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5533 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5534 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5535 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5536 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5537 Torque Converter Clutch Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5538 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5539 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5540 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5541 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5542 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5543 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5544 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5545 Solenoid Operation Chart Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5546 Torque Converter Clutch Solenoid: Testing and Inspection 4R70E/4R75E Automatic Transmission Pinpoint Tests - OSC Equipped Vehicles Special Tools Any time an electrical connector or solenoid body is disconnected, inspect the connector for pin condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install a new connector or component as required. Shift Solenoids Pre-Diagnosis Use the following shift solenoid operation information when carrying out Pinpoint Test A. See: Transmission Control Systems/Testing and Inspection/Pinpoint Tests/Pinpoint Tests/Test A: Shift and Torque Converter Clutch Solenoids Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5547 Solenoid Operation Chart Shift Solenoid Failure Mode Chart "Always off" (Part 1) Shift Solenoid Failure Mode Chart "Always off" (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5548 Shift Solenoid Failure Mode Chart "Always off" (Part 3) Failed off due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck off. Shift Solenoid Failure Mode Chart "Always On" (Part 1) Shift Solenoid Failure Mode Chart "Always On" (Part 2) Shift Solenoid Failure Mode Chart "Always On" (Part 3) Failed on due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck on. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5549 Torque Converter Clutch Solenoid: Service and Repair 4R70E/4R75E Electronic Pressure Control (EPC) Solenoid Special Tools Removal CAUTION: Do not pull on the molded 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. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid and remove the transmission fluid pan and filter. 3. 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 interconnector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5550 4. Remove the EPC solenoid. Installation 1. NOTE: Lubricate the EPC solenoid O-rings with clean automatic transmission fluid. Install the EPC solenoid, bracket and bolt. ^ Tighten to 10 Nm (89 inch lbs.). 2. Inspect the lead frame for damage. ^ Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted. ^ If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, ^ Install a new lead frame. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5551 3. Connect the molded lead frame to the solenoids. 1 Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 2 Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 3 Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 4 Connect the bulkhead interconnector by pressing it in place by hand and fully seating the connector in place. 4. Install the transmission fluid pan and filter. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 4R70E/4R75E Automatic Transmission 1-2 Accumulator Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid and remove the transmission fluid pan and filter. 3. Compress the 1-2 accumulator piston and remove the accumulator piston retaining ring. 4. Remove the 1-2 shift accumulator assembly. 1 Remove the 1-2 accumulator cover. 2 Remove the inner and outer 1-2 accumulator springs. 3 Remove the 1-2 accumulator piston. 4 Remove the 1-2 accumulator upper spring. Installation 1. Install the 1-2 shift accumulator assembly. 1 Install the 1-2 accumulator upper spring. 2 Install the 1-2 accumulator piston. 3 Install the inner and outer 1-2 accumulator springs. 4 Install the 1-2 accumulator cover. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 1-2 Accumulator > Page 5556 2. Compress the 1-2 accumulator piston and remove the accumulator piston retaining ring. 3. Install the transmission fluid pan and filter. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 1-2 Accumulator > Page 5557 Accumulator: Service and Repair 2-3 Accumulator 4R70E/4R75E Automatic Transmission 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Application and ID > 4R70E/4R75E Automatic Transmission Band: Application and ID 4R70E/4R75E Automatic Transmission Clutch Pressure Chart (Part 1) Clutch Pressure Chart (Part 2) Band and Clutch Application Chart A Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Application and ID > 4R70E/4R75E Automatic Transmission > Page 5562 Band and Clutch Application Chart B Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Application and ID > 4R70E/4R75E Automatic Transmission > Page 5563 Band: Application and ID 6HP26 Automatic Transmission Clutch Application Chart (Part 1) Clutch Application Chart (Part 2) Clutch Application Chart (Part 3) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Reverse Servo Assembly Band Apply Servo: Service and Repair Reverse Servo Assembly 4R70E/4R75E Automatic Transmission Reverse Servo Assembly Special Tools Removal 1. Remove the main control valve body. 2. Using the special tool, remove the reverse band servo retaining ring. 1 Compress the servo spring. 2 Remove the reverse band servo retaining ring. 3. Remove the reverse servo assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Reverse Servo Assembly > Page 5568 1 Remove the reverse band servo cover. 2 Remove the reverse band servo piston and rod. 3 Remove the reverse band servo spring. 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 return spring and piston. ^ Do not install the piston cover. 2. Install the special tool and tighten the band apply bolt. ^ Tighten to 5.6 Nm (50 inch lbs.). 3. Attach the special tool to the transmission. ^ Position the indicator stem on the flat portion of the reverse servo piston and zero the dial indicator. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Reverse Servo Assembly > Page 5569 4. Loosen the bolt until the piston stops against the tool. 5. Verify that the amount of piston travel on the dial indicator is within specification. 6. If piston travel is not within specification, select and install the correct servo piston assembly to bring the servo piston travel within specification. 1 One groove 2 Two groove 3 Three groove 7. Remove the dial indicator and servo selection tool. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Reverse Servo Assembly > Page 5570 8. Install the correct reverse servo assembly. 1 Install the reverse band servo spring. 2 Install the reverse band servo piston and rod. 3 Install the reverse band servo cover. 9. Using the special tool, 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Reverse Servo Assembly > Page 5571 Band Apply Servo: Service and Repair Overdrive Servo 4R70E/4R75E Automatic Transmission Overdrive Servo Special Tools Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the main control valve body. 3. NOTE: If the 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. Using the special tool, compress the servo spring to remove the overdrive servo retaining ring. 4. Remove the overdrive servo piston and return spring. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Reverse Servo Assembly > Page 5572 1. Install the overdrive servo piston assembly. 1 Install the overdrive servo piston return spring. 2 Install the overdrive servo piston assembly. 2. Use the special tool to install the overdrive servo piston retaining ring. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions Brake Switch - TCC: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5577 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5578 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5579 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5580 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5581 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5582 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5583 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5584 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5585 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5586 Brake Switch - TCC: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5587 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5588 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5589 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5590 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5591 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5592 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5593 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Page 5594 Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - BPP switch is hardwired to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - BPP switch is hardwired to the Anti-Lock Brake System (ABS) Module, Lighting Control Module (LCM), or Rear Electronic Module (REM), the BPP signal is then broadcast over the network to be received by the PCM. - BPP switch is hardwired to the anti-lock brake system (ABS) traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid .............................................................................................................................. .............................................. 13.9 quarts (13.1 liters) NOTE: Indicates only approximate dry-fill capacity. Some applications may vary based on cooler size and if equipped with an in-tank cooler. The amount of transmission fluid and fluid level should be set by the indication on the dipsticks normal operating range. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 5599 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Fluid Type ............................................................................................................................................ ............................................. MERCON V XT-5-QM Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission Fluid - A/T: Service and Repair 6HP26 Automatic Transmission Transmission Fluid Cooler Backflushing and Cleaning 6HP26 Automatic Transmission Transmission Fluid Cooler Backflushing and Cleaning Material CAUTION: When internal damage occurs in the transmission, metal particles and clutch plate material can travel into the torque converter and the transmission fluid cooler. These contaminates are a major cause of recurring transmission concerns. To prevent further concerns, remove these contaminates from the cooler lines and install a new cooler before placing the transmission in use. 1. Install a new transmission fluid cooler if any fluid leak are indicated or a major metallic failure is indicated. 2. Using a suitable torque converter/fluid cooler cleaner, flush the fluid cooler and lines. 3. NOTE: Rubber hoses must be attached to the ends of the fluid cooler tubes, to aid in connecting them to the cleaner. Connect the cleaner pressure and return lines appropriately. 1 Connect the pressure line to the fluid cooler inlet tube. 2 Connect the return line to the fluid cooler outlet tube. 3 Place the outlet end of the return line in the fluid tank reservoir. 4. NOTE: Cycling the fluid pump on and off will help dislodge contaminants in the cooler system. Switch the fluid pumps on. Allow the fluid to circulate a minimum of 5 minutes. 5. Switch the fluid pump off. 6. Disconnect the cleaner pressure line at the fluid cooler tube. 7. Using compressed air, blow through the fluid cooler inlet tube until all fluid is removed. 8. Remove the rubber hoses from the fluid cooler tubes. Transmission Fluid Drain and Refill Transmission Fluid Drain and Refill Special Tools Material Drain Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 5602 CAUTION: The fluid fill plug located on the side of the transmission is near the exhaust system. The exhaust will be extremely hot during this procedure. Use care when working near the exhaust and the heat shields. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove and discard the fluid pan drain plug and allow the fluid to drain. Refill 1. Install a new fluid pan drain plug. ^ Tighten to 8 Nm (71 inch lbs.). 2. Remove the fluid fill plug located on the RH rear side of the case, near the transmission electrical connector. 3. CAUTION: The use of any other transmission fluid than specified can result in the transmission failing to operate in a normal manner or Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 5603 transmission failure. Fill the transmission. ^ Add 4.7 liters (5 quarts) of clean automatic transmission fluid to the transmission through the fluid fill hole. Stop when the fluid runs out of the bottom of the hole. 4. Install the fluid fill plug located on the RH rear side of the case, near the transmission electrical connector. ^ Tighten to 35 Nm (26 ft. lbs.). 5. Start the engine. Move the transmission range selector lever through all the gear ranges, checking for engagements. 6. With the special tool connected, the engine idling (600 - 750 rpm) in PARK and the transmission temperature at 30°C - 50°C (86°F - 122°F), check and adjust the transmission fluid level. 7. If more fluid is needed, remove the fluid fill plug on the side of the case and fill with clean automatic transmission fluid until the fluid runs out of the bottom of the hole. Check Fluid Level and Condition Check Fluid Level and Condition Fluid Level Check CAUTION: The vehicle should not be driven if the fluid level is low as internal failure could result. NOTE: If the vehicle has been operated for an extended period at high highway speeds, in city traffic, during hot weather or while pulling a trailer, the fluid must cool down to obtain an accurate reading. NOTE: The transmission fluid temperature must not be allowed to exceed 50°C (122°F) when checking the fluid level. The fluid temperature should be between 30°C - 50°C (86°F - 122°F) closer to 50°C (122°F) when checking the fluid level. This vehicle is not equipped with a fluid level indicator. An incorrect level may affect the transmission operation and can result in transmission failure. Under normal circumstances, the fluid level should not be checked during normal maintenance. If the transmission starts to slip, shifts slowly or shows signs of fluid leaking, the fluid level should be checked. 1. With the transmission in P (PARK), the engine at idle (600 - 750 rpm) and foot pressed on the brake, move the range selector lever through each gear and allow engagement of each gear. Place the transmission range selector lever in the P position. 2. With the engine idling (600 - 750 rpm) in PARK, position it on a hoist. 3. Remove the fluid fill plug located on the side of the transmission case. 4. Partially add fluid until fluid starts to come out. Wait until the fluid stops or just drips from the hole. 5. Install the fluid fill plug. ^ Tighten to 35 Nm (26 ft. lbs.). High Fluid Level CAUTION: A fluid level that is too high can cause the fluid to become aerated due to the churning action of the rotating internal parts. This will Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 5604 cause erratic control pressure, foaming, loss of fluid from the vent tube and possible transmission failure. If an overfill reading is indicated, drain and refill the transmission. Low Fluid Level A low fluid level can result in poor transmission engagement, slipping or failure. This may 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 can result in transmission failure. If fluid must be added, add fluid in 0.5 liter (1/2 quart)increments through the fluid fill plug. Do not overfill the fluid. For fluid type, refer to the specification chart. Fluid Condition Check 1. Check the fluid level. 2. Remove the fluid fill plug and allow the fluid to drip onto a facial tissue and examine the stain. 3. NOTE: The transmission fluid could be 2 different colors. The factory fill fluid is clear. The replacement fluid is red. Observe the color and the odor. The color under normal circumstances should be dark reddish or clear, not black or have a burnt odor. 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 and fluid cooler tubes. A new oil-to-air cooler must be installed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 5605 Fluid - A/T: Service and Repair 4R70E/4R75E Automatic Transmission Transmission Fluid Cooler Backflushing and Cleaning Transmission Fluid Cooler Backflushing and Cleaning Material 1. CAUTION: Do not use any supplemental transmission fluid additives or cleaning agents. The use of these products could cause internal transmission components to fail; this will effect the operation of the transmission. Conduct backflushing with a suitable torque converter/fluid cooler cleaner. Test your equipment to make sure that a vigorous fluid flow is present before proceeding. Install a new filter in the flush equipment if flow is weak or contaminated. 2. If equipped, remove and discard the transmission fluid in-line filter. 3. Remove the transmission fluid cooler bypass valve and install rubber hoses in its place. 4. To aid in attaching the cleaner to the transmission steel cooler lines, connect 2 additional rubber hoses to the transmission end of the steel transmission cooler lines as described below. ^ Connect the cleaner tank pressure line to the steel transmission cooler return line (longest line). ^ Connect a tank return hose to the steel transmission cooler pressure line (shorter line). Place the outlet end of this hose in the tank reservoir. 5. Turn on the pump and allow the fluid to circulate a minimum of 5 minutes (cycling switch on and off will help dislodge contaminants in cooler system). 6. Switch off the pump and disconnect the pressure hose from the transmission cooler return line. 7. Use compressed air to blow out the cooler(s) and lines (blow air into the transmission cooler return line) until all fluid is removed. 8. Remove the rubber return hose from the remaining steel cooler line. 9. Remove the rubber hoses and reinstall the transmission fluid cooler bypass valve. Transmission Fluid Drain and Refill Transmission Fluid Drain and Refill Special Tools Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 5606 special Tools Draining, all vehicles using a suitable flush and fill machine CAUTION: Always refer to the instructions supplied with the flush and fill machine. NOTE: Draining fluid from the transmission by removing only the fluid pan is acceptable for normal or severe duty fluid maintenance. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Use a suitable flush and fill machine to change the fluid. 3. When connecting the flush and fill machine, connect the machine to the fluid cooler tube after the fluid cooler on the cooler return line. This will help remove any foreign material trapped in the fluid coolers. Refill 1. Use only clean automatic transmission fluid. 2. Once the fluid exchange has been completed, disconnect the flush and fill machine. Reconnect any disconnected fluid cooler tubes. 3. With the engine running and the transmission at normal operating temperature 66 - 77°C (150 - 170°F), check and adjust the transmission fluid level and check for any leaks. If fluid is needed, add fluid in increments of 0.24 liter (0.5 pint) until the correct level is achieved (fluid should be in the cross-hatched area of the fluid level indicator). Draining, all vehicles not using a suitable flush and fill machine 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Loosen the transmission fluid pan bolts and allow the fluid to drain. 3. After the fluid has drained, remove the transmission fluid pan. 4. Do not remove the fluid filter. It is not necessary to change the fluid filter during a normal maintenance fluid change. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 5607 5. Clean and inspect the transmission fluid pan, transmission fluid pan gasket and magnet. 6. Thoroughly flush the cooler tubes. Refill 1. Position the magnet into the transmission fluid pan. 2. NOTE: The fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the gasket should be reused. Install the fluid pan and gasket. 1 Position the fluid pan with the gasket in place. 2 Install the bolts. 1 Tighten to 14 Nm (10 ft. lbs.). 3. CAUTION: The use of any other transmission fluid can result in the transmission failing to operate in a normal manner or transmission failure. Fill the transmission. Add 4.7 liters (5 qts) of clean automatic transmission fluid to the transmission through the fluid filler tube. 4. Start the engine. Move the transmission range selector lever through all the gear ranges, checking for engagements. 5. With the engine running and the transmission at normal operating temperature 66 - 77°C (150 - 170°F), check and adjust the transmission fluid level and check for any leaks. If fluid is needed, add fluid in increments of 0.24 liter (0.5 pint) until the correct level is achieved (fluid should be in the cross-hatched area of the fluid level indicator). Check Fluid Level and Condition Check Fluid Level and Condition 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. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 5608 NOTE: If vehicle has been operated for an extended period of time at highway speeds, in city traffic, in hot weather or when 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, shifts 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 drain and refill the transmission. 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 type of transmission fluid other than specified could result in transmission malfunction and/or damage. If fluid needs to be added, add fluid in 0.25L (1/2 pint) increments through the filler tube. Do not overfill the fluid. For fluid type, refer to the General Specifications chart. 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. 7. Carry out diagnostic checks and adjustments; refer to Diagnosis By Symptom See: Transmission Control Systems/Testing and Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 5609 Inspection/Symptom Related Diagnostic Procedures/4R70E/4R75E/Diagnosis By Symptom. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Transmission Fluid In-Line Filter Fluid Filter - A/T: Service and Repair Transmission Fluid In-Line Filter 4R70E/4R75E Automatic Transmission Transmission Fluid In-Line Filter Special Tools Transmission Fluid In-line Filter with an OTA cooler NOTE: Use the following guidelines for installing the transmission fluid in-line filter: ^ If the transmission was overhauled and the vehicle was equipped with an in-line fluid filter, install a new in-line fluid filter. ^ If the transmission was overhauled and the vehicle was not equipped with an in-line fluid filter, install a new in-line fluid filter kit. ^ If the transmission is being installed for a non-internal repair, do not install an in-line filter or filter kit. ^ If installing a new or a Ford-authorized remanufactured transmission, install the in-line transmission fluid filter that is supplied. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If equipped, remove the bolts and the skid plate. 3. Remove the section of the rubber hose and steel line as illustrated. ^ Clean and de-burr the end of the steel line. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Transmission Fluid In-Line Filter > Page 5614 4. NOTE: Be sure the cooler tube is fully seated in the body of the fitting before final tightening of the ferrule nut. Install the tubing ferrule hose assembly connector onto the end of the steel fluid cooler tube. Finger-tighten the ferrule nut, then tighten the nut an additional 1-1/2 turns to seat the ferrule in the connector. 5. CAUTION: The filter has a bypass valve in it. The red arrow on the filter indicates the direction of fluid flow through the filter. The filter must be installed in the fluid cooler return line with the red arrow on the filter pointing away from the transmission fluid cooler and toward the transmission (the return line has fluid coming out of the cooler going to the transmission). If the fluid filter is not installed correctly, it will cause internal transmission damage. CAUTION: Do not install any rubber hoses or steel tubing with a bend entering the filter greater than 60 degrees. Using a suitable length of hose install the filter. Tighten the hose clamps. 6. Clean a section of the transmission fluid pan and install the sticker. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Transmission Fluid In-Line Filter > Page 5615 7. If equipped, install the skid plate and the bolts. 8. Fill the transmission with clean automatic transmission fluid. ^ Verify for correct operation. ^ Check the filter for leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Transmission Fluid In-Line Filter > Page 5616 Fluid Filter - A/T: Service and Repair Transmission Fluid In-Line Filter - Without an OTA Cooler 4R70E/4R75E Automatic Transmission Transmission Fluid In-line Filter - without an OTA cooler NOTE: Use the following guidelines for installing the transmission fluid in-line filter: ^ If the transmission was overhauled and the vehicle was equipped with an in-line fluid filter, install a new in-line fluid filter. ^ If the transmission was overhauled and the vehicle was not equipped with an in-line fluid filter, install a new in-line fluid filter kit. ^ If the transmission is being installed for a non-internal repair, do not install an in-line filter or filter kit. ^ If installing a new or a Ford-authorized remanufactured transmission, install the in-line transmission fluid filter that is supplied. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the cooler tubes retainers. 3. Remove the section of the steel tube as illustrated. ^ Clean and de-burr the end of the steel tubes. 4. NOTE: Be sure the cooler tube is fully seated in the body of the fitting before final tightening of the ferrule nut. Install the tubing ferrule hose assembly connector onto the end of the steel fluid cooler tubes. Finger-tighten the ferrule nut, then tighten the nut an additional 1-1/2 turns to seat the ferrule in the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Transmission Fluid In-Line Filter > Page 5617 5. CAUTION: The filter has a bypass valve in it. The red arrow on the filter indicates the direction of fluid flow through the filter. The filter must be installed in the fluid cooler return line with the red arrow on the filter pointing away from the transmission fluid cooler and toward the transmission (the return line has fluid coming out of the cooler going to the transmission). If the fluid filter is not installed correctly, it will cause internal transmission damage. CAUTION: Do not install any rubber hoses or steel tubing with a bend entering the filter greater than 60 degrees. Using a suitable length of hose install the filter. Tighten the hose clamps. 6. Install one cooler tube retainer as Illustrated. 7. Secure the cooler tubes together with a tie strap. 8. Clean a section of the transmission fluid pan and install the sticker. 9. Fill the transmission with clean automatic transmission fluid. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Transmission Fluid In-Line Filter > Page 5618 ^ Verify for correct operation. ^ Check the filter for leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Transmission Fluid In-Line Filter > Page 5619 Fluid Filter - A/T: Service and Repair Fluid Pan, Gasket and Filter 4R70E/4R75E Automatic Transmission Fluid Pan, Gasket and Filter Material Removal CAUTION: Do not use any supplemental transmission fluid additives or cleaning agents. The use of these products could cause internal transmission components to fail; this will effect the operation of the transmission. Use of a fluid other than specified could result in transmission failure. NOTE: Normal maintenance requires periodic automatic transmission fluid changes. If a major repair, such as a clutch, band, bearing, etc., is required, the automatic transmission will need to be removed for repair. The transmission fluid needs to be changed if evidence of fluid contamination is found. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid. ^ Loosen the transmission fluid pan bolts and allow fluid to drain. After fluid is drained remove the bolts. 3. Remove the transmission fluid pan and transmission fluid pan gasket. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Transmission Fluid In-Line Filter > Page 5620 4. Pull down evenly and remove the transmission fluid filter and seal. 5. Clean and inspect the transmission fluid pan, gasket and magnet. Installation 1. 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. Install a new fluid filter and seal as required. 2. Position the pan magnet into the transmission fluid pan. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Transmission Fluid In-Line Filter > Page 5621 3. 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 and gasket. 2 Install the transmission fluid pan bolts. ^ Tighten to 14 Nm (10 ft. lbs.). 4. NOTE: When filling a dry transmission and converter, start with a minimum of 4.7 liters (5 quarts). Fill the transmission to the correct level with clean automatic transmission fluid. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission Fluid Line/Hose: Service and Repair 6HP26 Automatic Transmission Transmission Fluid Cooler Tubes Special Tools Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Separate the fluid cooler lines. 3. Using the special tool, disconnect the fluid cooler tube from the auxiliary transmission fluid cooler. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 5626 4. Remove the transmission fluid cooler tube retainer from the front of the engine. 5. Remove the transmission fluid cooler tube rear support bracket from the side of the transmission. 6. NOTE: The cooler tube band seals and backer rings may remain in the transmission case. Carefully remove them from the case if retained. ^ Disconnect the transmission fluid cooler tubes from the transmission. 7. Disconnect the engine oil level sensor electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 5627 8. If equipped, remove the RH bolt and nut for the front axle, lower the RH side of the axle. 9. Remove the 4 nuts and lower the front sway bar. 10. Using the special tool, disconnect the fluid cooler tube from the auxiliary transmission fluid cooler. 11. Disconnect the secondary latch from the upper transmission fluid cooler connector at the radiator. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 5628 12. Using the special tool, disconnect the upper transmission fluid cooler tube from the radiator. 13. Disconnect the secondary latch from the lower transmission fluid cooler connector at the radiator. 14. Using the special tool, disconnect the lower transmission fluid cooler tube from the radiator. 15. Remove the transmission fluid cooler tubes from the vehicle. Installation 1. Position the transmission fluid cooler tubes in the vehicle. 2. Connect the lower transmission fluid cooler tube to the radiator. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 5629 3. Install the secondary latch to the lower transmission fluid cooler tube at the radiator. 4. Connect the upper transmission fluid cooler tube to the radiator. 5. Install the secondary latch to the upper transmission fluid cooler tube at the radiator. 6. NOTE: Inspect the case to make sure that the old band seals and backer rings are not stuck in the case. NOTE: Install new band seals and backer rings on the ends of the cooler lines prior to installing. Install new seals on the transmission fluid cooler tubes. 1 Transmission fluid cooler tube. 2 Retainer plate. 3 Backer ring. 4 Band seal. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 5630 7. NOTE: Inspect the case to make sure that the old band seals and backer rings are not stuck in the case. NOTE: Install new band seals and backer rings on the ends of the cooler lines prior to installing. Position the fluid cooler lines into the transmission, then install the bolt for the transmission cooler line retainer. ^ Tighten to 23 Nm (17 ft. lbs.). 8. Install the transmission fluid cooler tube retainer to the side of the transmission. ^ Tighten to 48 Nm (35 ft. lbs.). 9. Install the transmission fluid cooler tube retainer to the front of the engine. ^ Tighten to 25 Nm (18 ft. lbs.). 10. Connect the fluid cooler tubes into the auxiliary transmission fluid cooler. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 5631 11. Position the sway bar in place and install the 4 nuts. ^ Tighten to 55 Nm (41 ft. lbs.). 12. If removed, position the axle and install the RH bolt and nut. ^ Tighten to 102 Nm (75 ft. lbs.). 13. Connect the engine oil level sensor electrical connector. 14. With the vehicle idling (600 - 750 rpm) in PARK, and the transmission temperature at 30°C - 50°C (86°F - 122°F), check and adjust the transmission fluid level. 15. CAUTION: The fluid fill plug located on the side of the transmission is near the exhaust system. The exhaust will be extremely hot during this procedure. Use care when working near the exhaust and the heat shields. Remove the fluid fill plug located on the RH rear side of the case near the transmission electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 5632 16. CAUTION: The use of any other transmission fluid can result in the transmission failing to operate in a normal manner or transmission failure. CAUTION: The fluid fill plug located on the side of the transmission is near the exhaust system. The exhaust will be extremely hot during this procedure. Use care when working near the exhaust and the heat shields. Fill the transmission. ^ Add clean automatic transmission fluid to the transmission through the fluid fill hole. ^ Stop when the fluid runs out of the bottom of the hole. 17. CAUTION: The fluid fill plug located on the side of the transmission is near the exhaust system. The exhaust will be extremely hot during this procedure. Use care when working near the exhaust and the heat shields. Install the fluid fill plug. ^ Tighten to 35 Nm (26 ft. lbs.). 18. Move the transmission range selector lever through all the gear ranges, checking for engagements. 19. CAUTION: The fluid fill plug located on the side of the transmission is near the exhaust system. The exhaust will be extremely hot during this procedure. Use care when working near the exhaust and the heat shields. If more fluid is needed, start the engine. ^ Remove the fluid fill plug on the side of the case, fill with clean automatic transmission fluid until fluid adjust starts to dribble out of the hole. ^ Install the fill plug. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 5633 Fluid Line/Hose: Service and Repair 4R70E/4R75E Automatic Transmission Transmission Fluid Cooler Tubes , With Auxiliary Transmission Fluid Cooler Transmission Fluid Cooler Tubes, With Auxiliary Transmission Fluid Cooler Special Tools Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the transmission fluid cooler tubes from the transmission. 3. Disconnect the transmission fluid cooler tubes from the thermostatic valve. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 5634 4. Remove the transmission fluid cooler tube retainer from the front of the engine. 5. Using the special tool, disconnect the fluid cooler tube from the auxiliary transmission fluid cooler. 6. Using the special tool, disconnect the fluid cooler tube from the auxiliary transmission fluid cooler. 7. Remove the secondary latch from the upper transmission fluid cooler tube at the radiator. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 5635 8. Using the special tool, disconnect the upper transmission fluid cooler tube from the radiator. 9. Remove the secondary latch from the lower transmission fluid cooler tube at the radiator. 10. Using the special tool, disconnect the lower transmission fluid cooler tube from the radiator. 11. Remove the transmission fluid cooler tubes from the vehicle. Installation 1. Position the transmission fluid cooler tubes in the vehicle. 2. Connect the lower transmission fluid cooler tube to the radiator. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 5636 3. Install the secondary latch to the lower transmission fluid cooler tube at the radiator. 4. Connect the upper transmission fluid cooler tube to the radiator. 5. Install the secondary latch to the upper transmission fluid cooler tube at the radiator. 6. Connect the fluid cooler tubes into the auxiliary transmission fluid cooler. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 5637 7. Install the transmission fluid cooler tube retainer to the front of the engine. ^ Tighten to 25 Nm (18 ft. lbs.). 8. Connect the transmission fluid cooler tubes to the thermostatic valve. ^ Tighten to 20 Nm (15 ft. lbs.). 9. Connect the transmission fluid cooler tubes to the transmission. ^ Tighten to 20 Nm (15 ft. lbs.). 10. Fill the transmission with the specified type and quantity of transmission fluid. 11. Check for leaks. Transmission Fluid Cooler Tubes, Without Auxiliary Transmission Fluid Cooler Transmission Fluid Cooler Tubes, Without Auxiliary Transmission Fluid Cooler Special Tools Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 5638 Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the transmission fluid cooler tubes from the transmission. 3. Disconnect the transmission fluid cooler tubes from the thermostatic valve. 4. Remove the transmission fluid cooler tube retainer from the front of the engine. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 5639 5. Remove the secondary latch from the upper transmission fluid cooler tube at the radiator. 6. Using the special tool, disconnect the upper transmission fluid cooler tube from the radiator. 7. Remove the secondary latch from the lower transmission fluid cooler tube at the radiator. 8. Using the special tool, disconnect the lower transmission fluid cooler tube from the radiator. 9. Remove the transmission fluid cooler tubes from the vehicle. Installation 1. Position the transmission fluid cooler tubes in the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 5640 2. Connect the lower transmission fluid cooler tube to the radiator. 3. Install the secondary latch to the lower transmission fluid cooler tube at the radiator. 4. Connect the upper transmission fluid cooler tube to the radiator. 5. Install the secondary latch to the upper transmission fluid cooler tube at the radiator. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 5641 6. Install the transmission fluid cooler tube retainer to the front of the engine. ^ Tighten to 25 Nm (18 ft. lbs.). 7. Connect the transmission fluid cooler tubes to the thermostatic valve. ^ Tighten to 20 Nm (15 ft. lbs.). 8. Connect the transmission fluid cooler tubes to the transmission. ^ Tighten to 20 Nm (15 ft. lbs.). 9. Fill the transmission with the specified type and quantity of transmission fluid. 10. Check for leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications 4R70E/4R75E Automatic Transmission Install the transmission fluid pan bolts. Tighten to ............................................................................................................................................. ........................................ 14 Nm (10 ft. lbs.). 6HP26 Automatic Transmission Install a new fluid pan and tighten the bolts in a crisscross pattern. Tighten to ............................................................................................................................................. ....................................... 8 Nm (71 inch lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 5645 Fluid Pan: Service and Repair 4R70E/4R75E Automatic Transmission Fluid Pan, Gasket and Filter Material Removal CAUTION: Do not use any supplemental transmission fluid additives or cleaning agents. The use of these products could cause internal transmission components to fail; this will effect the operation of the transmission. Use of a fluid other than specified could result in transmission failure. NOTE: Normal maintenance requires periodic automatic transmission fluid changes. If a major repair, such as a clutch, band, bearing, etc., is required, the automatic transmission will need to be removed for repair. The transmission fluid needs to be changed if evidence of fluid contamination is found. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid. ^ Loosen the transmission fluid pan bolts and allow fluid to drain. After fluid is drained remove the bolts. 3. Remove the transmission fluid pan and transmission fluid pan gasket. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 5646 4. Pull down evenly and remove the transmission fluid filter and seal. 5. Clean and inspect the transmission fluid pan, gasket and magnet. Installation 1. 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. Install a new fluid filter and seal as required. 2. Position the pan magnet into the transmission fluid pan. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 5647 3. 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 and gasket. 2 Install the transmission fluid pan bolts. ^ Tighten to 14 Nm (10 ft. lbs.). 4. NOTE: When filling a dry transmission and converter, start with a minimum of 4.7 liters (5 quarts). Fill the transmission to the correct level with clean automatic transmission fluid. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation TRANSMISSION CONTROL INDICATOR LAMP (TCIL) The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations View 151-14 (Steering Column) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Overdrive Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5657 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5658 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5659 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5660 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5661 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5662 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5663 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5664 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5665 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5666 Overdrive Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5667 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5668 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5669 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5670 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5671 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5672 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5673 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5674 C2135 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Pressure Regulating Solenoid: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5679 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5680 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5681 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5682 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5683 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5684 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5685 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5686 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5687 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5688 Pressure Regulating Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5689 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5690 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5691 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5692 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5693 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5694 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5695 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5696 Solenoid Operation Chart Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5697 Pressure Regulating Solenoid: Testing and Inspection 4R70E/4R75E Automatic Transmission Pinpoint Tests - OSC Equipped Vehicles Special Tools Any time an electrical connector or solenoid body is disconnected, inspect the connector for pin condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install a new connector or component as required. Shift Solenoids Pre-Diagnosis Use the following shift solenoid operation information when carrying out Pinpoint Test A. See: Transmission Control Systems/Testing and Inspection/Pinpoint Tests/Pinpoint Tests/Test A: Shift and Torque Converter Clutch Solenoids Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5698 Solenoid Operation Chart Shift Solenoid Failure Mode Chart "Always off" (Part 1) Shift Solenoid Failure Mode Chart "Always off" (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5699 Shift Solenoid Failure Mode Chart "Always off" (Part 3) Failed off due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck off. Shift Solenoid Failure Mode Chart "Always On" (Part 1) Shift Solenoid Failure Mode Chart "Always On" (Part 2) Shift Solenoid Failure Mode Chart "Always On" (Part 3) Failed on due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck on. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5700 Pressure Regulating Solenoid: Service and Repair 4R70E/4R75E Electronic Pressure Control (EPC) Solenoid Special Tools Removal CAUTION: Do not pull on the molded 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. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid and remove the transmission fluid pan and filter. 3. 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 interconnector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5701 4. Remove the EPC solenoid. Installation 1. NOTE: Lubricate the EPC solenoid O-rings with clean automatic transmission fluid. Install the EPC solenoid, bracket and bolt. ^ Tighten to 10 Nm (89 inch lbs.). 2. Inspect the lead frame for damage. ^ Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted. ^ If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, ^ Install a new lead frame. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5702 3. Connect the molded lead frame to the solenoids. 1 Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 2 Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 3 Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 4 Connect the bulkhead interconnector by pressing it in place by hand and fully seating the connector in place. 4. Install the transmission fluid pan and filter. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission Seals and Gaskets: Service and Repair 6HP26 Automatic Transmission Output Shaft Seal Output Shaft Seal Special Tools Material Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 4x2 vehicles 2. Remove the rear driveshaft. 3. Remove and discard the output shaft flange nut. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5707 4. Remove the output shaft flange. 5. Remove the output shaft seal. 4x4 vehicles 6. Remove the transfer case. 7. Remove the 11 bolts and the extension housing. 8. Remove the output shaft seal. Installation 4x2 vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5708 1. Position a new output shaft seal. 2. Using the special tool, install the output shaft seal. 3. Install the output shaft flange. 4. Install a new output shaft flange nut. ^ After installing the new nut, it must be staked at the slots to prevent it from coming loose. ^ Tighten to 120 Nm (89 ft. lbs.). 5. Install the rear driveshaft. 4x4 vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5709 6. Position the output shaft seal. 7. Using the special tool, install a new output shaft seal. 8. Install the extension housing and the 11 bolts. ^ Tighten to 48 Nm (35 ft. lbs.). 9. Install the transfer case. All vehicles 10. Start the engine. Move the transmission range selector lever through all the gear ranges, checking for engagements. 11. With the engine idling (600 - 750 rpm) in PARK and the transmission temperature at 30°C - 50°C (86°F - 122°F), check and adjust the transmission fluid level. 12. CAUTION: The fluid fill plug located on the side of the transmission is near the exhaust system. The exhaust will be extremely hot during this procedure. Use care when working near the exhaust and the heat shields. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5710 With the engine still running and the vehicle in PARK, remove the fluid fill plug. The fill plug is located on the RH rear side of the case near the transmission electrical connector. 13. CAUTION: The use of any other transmission fluid than specified can result in the transmission failing to operate in a normal manner or transmission failure. Fill the transmission. ^ Add clean automatic transmission fluid to the transmission through the fluid fill hole. Stop when the fluid runs out of the bottom of the hole. 14. Install the fluid fill plug. ^ Tighten to 35 Nm (26 ft. lbs.). 15. With the engine still running in PARK, check the fluid level. If more fluid is needed, remove the fluid fill plug and fill with clean automatic transmission fluid until the fluid runs out of the bottom of the hole. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5711 16. Install the fluid fill plug. ^ Tighten to 35 Nm (26 ft. lbs.). Manual Control Lever Shaft and Seal Manual Control Lever Shaft and Seal Special Tools Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the shift cable end and remove the shift cable bracket bolts. Position the cable and bracket aside. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5712 3. Remove and discard the transmission fluid pan drain plug and allow the fluid to drain. 4. Install a new transmission fluid pan drain plug. ^ Tighten to 8 Nm (71 inch lbs.). 5. NOTE: The transmission fluid pan, gasket, filter and magnets are serviced as a complete unit. Remove the transmission fluid pan assembly. 6. CAUTION: Do not pull on the wire harness to disconnect the connector or damage to the connector will occur. Disconnect the main transmission electrical harness by twisting the outer shell and pulling back on the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5713 7. Press the release tab and pull down on the bulkhead connector retainer. 8. With the release tab down, pull the outer shell of the bulkhead electrical connector. 9. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit. Pull the outer shell of the bulkhead electrical connector out of the transmission. 10. Remove the 10 bolts from the mechatronic assembly and remove the mechatronic assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5714 11. Remove the park rod actuating plate. 12. Remove the manual control lever. 1 Remove the roll pin. 2 Slide the manual control lever shaft out of the case. 3 Hold the spacer to keep it from falling out of the case. 4 Remove the manual valve inner lever and the park rod as an assembly. 13. Remove and discard the manual control lever seal. Installation 1. Position a new manual control lever seal in place. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5715 2. Using the special tool, install a new manual control lever shaft seal. 3. Install the manual lever in the case. 1 Slide the manual lever in the case. 2 Position the spacer in place while sliding the manual lever into the spacer. 3 Position the manual valve inner lever while sliding the manual lever and lining up the roll pin hole. 4 Install the roll pin. 4. Position the park rod in place. Push down on the park pawl and position the park rod in place. 5. While holding the park rod down, install the park rod actuating plate. ^ Tighten to 10 Nm (89 inch lbs.). 6. Position the mechatronic assembly in place and loosely install the 10 bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5716 7. Tighten the mechatronic bolts in the sequence shown. ^ Tighten to 8 Nm (71 inch lbs.). 8. Install new O-rings on the outer shell of the bulkhead electrical connector. 9. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit. With the release tab down, push the outer shell of the bulkhead electrical connector into the transmission. 10. Press up on the tab and lock the outer shell of the bulkhead electrical connector in place. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5717 11. Install the transmission fluid pan. Tighten the bolts in a crisscross pattern. ^ Tighten to 8 Nm (71 inch lbs.). 12. Install the shift cable bracket bolts and connect the shift cable end. ^ Tighten to 48 Nm (35 ft. lbs.). 13. Connect the main transmission electrical harness by pushing it in and twisting the outer shell to lock it in place. 14. CAUTION: The fluid fill plug located on the side of the transmission is near the exhaust system. The exhaust will be extremely hot during this procedure. Use care when working near the exhaust and the heat shields. Remove the fluid fill plug. ^ The fill plug is located on the RH rear side of the case near the transmission electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5718 15. CAUTION: The use of any other transmission fluid than specified can result in the transmission failing to operate in a normal manner or transmission failure. Fill the transmission. ^ Add 4.7 liters (5 quarts) of clean automatic transmission fluid to the transmission through the fluid fill hole. Stop when the fluid runs out of the bottom of the hole. 16. Install the fluid fill plug. ^ Tighten to 35 Nm (26 ft. lbs.). 17. Start the engine. Move the transmission range selector lever through all the gear ranges, checking for engagements. 18. With the engine idling (600 - 750 rpm) in PARK and the transmission temperature at 30°C - 50°C (86°F - 122°F), check and adjust the transmission fluid level. 19. With the engine still running in PARK check the fluid level. If more fluid is needed, remove the fluid fill plug on the side of the case and fill with clean automatic transmission fluid until the fluid runs out of the bottom of the hole. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5719 20. Install the fluid fill plug. ^ Tighten to 35 Nm (26 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5720 Seals and Gaskets: Service and Repair 4R70E/4R75E Automatic Transmission Extension Housing Gasket Extension Housing Gasket Material Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 4x2 vehicles 2. NOTE: To maintain initial driveshaft balance, mark the rear driveshaft yoke and axle flange so they may be installed in their original positions. Mark the driveshaft flange and the rear pinion flange for correct alignment during assembly. 3. Remove the 4 driveshaft bolts and the driveshaft. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5721 4. Slide the driveshaft back enough to index-mark the driveshaft, the extension housing and the output shaft. Separate the driveshaft from the transmission. 4x4 vehicles 5. Remove the transfer case. All vehicles 6. Use the high-lift jack to support the transmission. 7. NOTE: RH shown, LH similar. Remove the 2 bolts retaining the heat shield to the transmission support crossmember. 8. Loosen, but do not remove the transmission-to-crossmember nuts. 9. Remove the crossmember-to-frame bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5722 10. Remove the transmission mount-to-crossmember nuts and remove the crossmember. 5.4L engines 11. Remove the nut from the exhaust bracket. 12. Remove the 2 bolts, the rear transmission mount and the exhaust hanger. 13. Lower the transmission to access the extension housing bolts. 14. Remove the fuel line bracket from the extension housing nut. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5723 15. NOTE: 4x2 shown, 4x4 similar. Remove the extension housing and gasket. 1 Remove the nuts and bolts. 2 Remove the extension housing and gasket. ^ Allow fluid to drain into suitable container. Installation All vehicles 1. NOTE: 4x2 shown, 4x4 similar. Install the extension housing and a new gasket. 1 Position the extension housing gasket and the extension housing. 2 Install the bolts and nuts. ^ Tighten to 27 Nm (20 ft. lbs.). 2. Install the fuel line bracket. ^ Tighten to 25 Nm (18 ft. lbs.). 3. Raise and position the transmission. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5724 4. Position the exhaust hanger, the rear transmission insulator and install the bolts. ^ Tighten to 80 Nm (59 ft. lbs.). 5. Install the exhaust bracket nut. ^ Tighten to 40 Nm (30 ft. lbs.). 6. Position the crossmember and loosely install the transmission mount-to-crossmember nut. 7. Install the crossmember-to-frame bolts. ^ Tighten to 90 Nm (66 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5725 8. Lower the transmission on the crossmember and tighten the rear mount nuts. ^ Tighten to 90 Nm (66 ft. lbs.). 9. NOTE: 4x2 shown, 4x4 similar. Remove the high-lift transmission Jack. 10. Install the 2 bolts retaining the heat shield to the transmission support crossmember. ^ Tighten to 15 Nm (11 ft. lbs.). 4x4 vehicles 11. Install the transfer case. 4x2 vehicles 12. NOTE: The output shaft and the driveshaft are a balanced assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5726 Install the driveshaft. ^ Align the yellow dots and position the driveshaft on the transmission. 13. NOTE: To maintain driveshaft balance, install the driveshaft yoke and flange in the original position that was marked during removal. Install the rear driveshaft and the 4 bolts. ^ Tighten to 103 Nm (76 ft. lbs.). All vehicles 14. Lower the vehicle. 15. Fill the transmission with clean automatic transmission fluid. ^ Verify for correct operation. ^ Check for leaks. Extension Housing Seal Extension Housing Seal Special Tools Material Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5727 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The output shaft and driveshaft are a balanced assembly. Mark the driveshaft flange and the rear pinion flange for correct alignment during assembly. 3. Remove the 4 driveshaft bolts. 4. Slide the driveshaft back enough to index-mark the driveshaft, the extension housing and the output shaft. Separate the driveshaft from the transmission. 5. Using the special tools, remove the extension housing seal. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5728 Installation 1. NOTE: When installing the new seal, make sure that the drain hole in the seal is in the 6 o'clock position. Using the special tool, install a new extension housing seal. 2. NOTE: The output shaft and the driveshaft are a balanced assembly. Install the driveshaft. ^ Align all the index marks and position the driveshaft on the transmission. ^ Install the driveshaft. 3. NOTE: To maintain driveshaft balance, install the driveshaft yoke and flange in the original position that was marked during removal. Install the rear driveshaft and the 4 bolts. ^ Tighten to 103 Nm (76 ft. lbs.). 4. Check the level of the transmission fluid, add clean automatic transmission fluid as necessary. Manual Control Lever Shaft and Seal Manual Control Lever Shaft and Seal Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5729 Special Tools Removal CAUTION: Use care not to damage the manual control lever shaft bore. The new seal can leak. CAUTION: Discard the outer manual control lever nut. NOTE: When removing the manual control lever shaft retaining pin, use a soft cloth to protect the surface of the case. All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 4x4 vehicles 2. Remove the front driveshaft shield nuts and remove the shield. 3. NOTE: Index-mark the front and rear flange. NOTE: It is not necessary to remove the front driveshaft from the vehicle. Index-mark the front and rear flange, disconnect the front driveshaft and position aside. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5730 All vehicles 4. Loosen, but do not remove the transmission fluid pan bolts and allow the fluid to drain. Once the fluid has drained, remove the bolts. 5. Remove the transmission fluid pan and gasket. 6. Disconnect the shift cable end. 7. Disconnect the digital transmission range (TR) electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5731 8. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control lever nut. 2 Remove the manual control lever. 9. Remove the digital TR sensor bolts and the sensor. 10. Remove the manual control valve detent lever bolt and spring. 11. Remove the manual control lever shaft retaining pin. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5732 12. Remove the inner manual control lever shaft nut and slide the manual control lever shaft out of the case. 13. Remove the manual control lever shaft seal. Installation All vehicles 1. Using the special tool, install the manual control lever seal. 2. Install the manual valve detent lever into the manual valve. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5733 3. Install the manual control lever shaft. 1 Install the manual control lever shaft. 2 Install the inner manual control lever shaft nut. ^ Tighten to 31 Nm (23 ft. lbs.). 3 Install the manual valve control lever shaft retaining pin. 4. Install the manual valve detent lever spring and bolt. ^ Tighten to 10 Nm (89 inch lbs.). 5. Install the digital TR sensor and loosely install the bolts. 6. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5734 7. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. Tighten the digital TR sensor bolts. ^ Tighten to 9 Nm (80 inch lbs.). 8. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual control lever nut. ^ Tighten to 33 Nm (24 ft. lbs.). 9. Connect the digital TR sensor electrical connector. 10. Connect the shift cable end to the manual lever with the lever in the (D) position. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5735 11. Position the pan magnet into the transmission fluid pan. 12. 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 and gasket. 2 Install the transmission fluid pan bolts. ^ Tighten to 14 Nm (10 ft. lbs.). 4x4 vehicles 13. Install the front driveshaft and align the index marks made during removal. Install the 4 bolts. ^ Tighten to 103 Nm (76 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 6HP26 Automatic Transmission > Page 5736 14. Install the front driveshaft shield and install the 2 nuts. ^ Tighten to 18 Nm (13 ft. lbs.). All vehicles 15. NOTE: Start by filling the transmission with 4.7 liters (5 quarts) of clean automatic transmission fluid. Fill the transmission to the correct level with clean automatic transmission fluid. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions Brake Switch - TCC: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5742 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5743 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5744 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5745 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5746 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5747 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5748 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5749 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5750 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5751 Brake Switch - TCC: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5752 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5753 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5754 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5755 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5756 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5757 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5758 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Page 5759 Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - BPP switch is hardwired to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - BPP switch is hardwired to the Anti-Lock Brake System (ABS) Module, Lighting Control Module (LCM), or Rear Electronic Module (REM), the BPP signal is then broadcast over the network to be received by the PCM. - BPP switch is hardwired to the anti-lock brake system (ABS) traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations View 151-14 (Steering Column) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Overdrive Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5765 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5766 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5767 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5768 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5769 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5770 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5771 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5772 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5773 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5774 Overdrive Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5775 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5776 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5777 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5778 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5779 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5780 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5781 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5782 C2135 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor/Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5787 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5788 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5789 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5790 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5791 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5792 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5793 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5794 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5795 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5796 Throttle Position Sensor/Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5797 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5798 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5799 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5800 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5801 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5802 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5803 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Mode Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5808 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5809 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5810 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5811 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5812 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5813 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5814 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5815 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5816 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5817 Transmission Mode Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5818 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5819 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5820 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5821 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5822 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5823 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5824 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 5825 Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH (TCS) Typical Transmission Control Switch (TCS) Typical Transmission Control Switch (TCS) The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature, the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage overdrive. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5829 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5832 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5833 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5834 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5835 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5836 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5837 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5838 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5839 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5840 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5841 Transmission Position Switch/Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5842 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5843 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5844 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5845 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5846 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5847 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5848 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5849 C167 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5850 Transmission Position Switch/Sensor: Adjustments 4R70E/4R75E Transmission Range (TR) Sensor Adjustment Special Tools 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual lever shift control cable. 3. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control lever nut. 2 Remove the manual control lever. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5851 4. Loosen the digital transmission range (TR) sensor bolts. 5. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 6. CAUTION: Tightening one bolt before tightening the other may cause the sensor to bind or become damaged. Using the special tool, align the digital TR sensor and tighten the bolts in an alternating sequence. ^ Tighten to 9 Nm (80 inch lbs.). 7. Install the manual control lever. ^ Position the manual control lever. 2 Install a new manual lever shaft outer nut. ^ Tighten to 33 Nm (24 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5852 8. With the manual lever in overdrive connect the shift lever control cable. 9. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5853 Transmission Position Switch/Sensor: Service and Repair 4R70E/4R75E Automatic Transmission Digital Transmission Range (TR) Sensor Special Tools Removal NOTE: Manual shift lever must be in the NEUTRAL position. 1. With the vehicle in NEUTRAL, position it on a hoist. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5854 2. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual control lever shift control cable. 3. Disconnect the digital TR electrical connector. 4. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control nut. 2 Remove the manual control lever. 5. Remove the digital TR sensor bolts and the digital TR sensor. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5855 1. Install the digital TR sensor and loosely install the bolts. 2. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 3. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. Tighten the digital TR sensor bolts. ^ Tighten to 9 Nm (80 inch lbs.). 4. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual control lever nut. ^ Tighten to 33 Nm (24 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5856 5. Connect the digital TR sensor electrical connector. 6. Connect the shift cable end to the manual lever with the lever in the (D) position. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Turbine Shaft Speed (TSS) Sensor > Page 5861 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Turbine Shaft Speed (TSS) Sensor > Page 5862 Transmission Speed Sensor: Locations Output Shaft Speed (OSS) Sensor View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Turbine Shaft Speed (TSS) Sensor > Page 5863 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Speed Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5866 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5867 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5868 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5869 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5870 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5871 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5872 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5873 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5874 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5875 Transmission Speed Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5876 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5877 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5878 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5879 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5880 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5881 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5882 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5883 Transmission Speed Sensor: Connector Views C193 C143 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5884 Transmission Speed Sensor: Service and Repair 4R70E/4R75E Automatic Transmission Speed Sensors Speed Sensors NOTE: Only remove the affected sensor. Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist, OSS sensor 2. Disconnect the output shaft speed (OSS) sensor electrical connector. 3. Remove the OSS sensor bolt. 4. Remove the OSS sensor. TSS sensor 5. Disconnect the turbine shaft speed (TSS) sensor electrical connector. 6. Remove the TSS sensor bolt. 7. Remove the TSS sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5885 Installation TSS sensor 1. Lubricate the O-ring seal and install the TSS sensor. 2. Install the TSS sensor bolt. ^ Tighten to 11 Nm (8 ft. lbs.). 3. Connect the TSS sensor electrical connector. OSS sensor 4. Lubricate the O-ring seal and install the OSS sensor. 5. Install the OSS sensor bolt. ^ Tighten to 12 Nm (9 ft. lbs.). 6. Connect the OSS sensor electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator Column Shift Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Column Shift Brake Shift Interlock Actuator Column Shift Brake Shift Interlock Actuator - Column Shift Removal and Installation 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 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 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator Column Shift > Page 5891 latches. Please refer to the appropriate vehicle shop manual to determine 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). Disconnect the battery ground cable. Wait at least one minute before proceeding with the procedure to allow the backup power supply to deplete its energy. 2. Remove the supplemental restraint system (SRS) steering column clockspring. 3. Remove the 3 bolts and remove the clockspring mounting bracket from the steering column. ^ To install, tighten to 6 Nm (53 inch lbs.). 4. Remove the 3 screws and position the wiring harnesses aside. 5. Disconnect the interlock actuator electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator Column Shift > Page 5892 6. Remove the 2 screws and position the actuator aside. 7. Remove the 2 bolts and position the selector lever detent bracket aside. ^ To install, tighten to 6 Nm (53 inch lbs.). 8. Remove the shift lock actuator from the detent bracket and remove the shift lock actuator. 9. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator Column Shift > Page 5893 Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Floor Shift Brake Shift Interlock Actuator Floor Shift Removal and Installation NOTE: The brake shift interlock actuator is not serviced individually. If replacement is required, install a new floor shift selector lever assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5898 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5899 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5900 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5901 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5902 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5903 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5904 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5905 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5906 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5907 Shift Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5908 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5909 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5910 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5911 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5912 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5913 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5914 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 5915 Solenoid Operation Chart Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 5916 Shift Solenoid: Testing and Inspection 4R70E/4R75E Automatic Transmission Pinpoint Tests - OSC Equipped Vehicles Special Tools Any time an electrical connector or solenoid body is disconnected, inspect the connector for pin condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install a new connector or component as required. Shift Solenoids Pre-Diagnosis Use the following shift solenoid operation information when carrying out Pinpoint Test A. See: Transmission Control Systems/Testing and Inspection/Pinpoint Tests/Pinpoint Tests/Test A: Shift and Torque Converter Clutch Solenoids Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 5917 Solenoid Operation Chart Shift Solenoid Failure Mode Chart "Always off" (Part 1) Shift Solenoid Failure Mode Chart "Always off" (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 5918 Shift Solenoid Failure Mode Chart "Always off" (Part 3) Failed off due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck off. Shift Solenoid Failure Mode Chart "Always On" (Part 1) Shift Solenoid Failure Mode Chart "Always On" (Part 2) Shift Solenoid Failure Mode Chart "Always On" (Part 3) Failed on due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck on. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 5919 Shift Solenoid: Service and Repair 4R70E/4R75E Electronic Pressure Control (EPC) Solenoid Special Tools Removal CAUTION: Do not pull on the molded 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. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid and remove the transmission fluid pan and filter. 3. 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 interconnector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 5920 4. Remove the EPC solenoid. Installation 1. NOTE: Lubricate the EPC solenoid O-rings with clean automatic transmission fluid. Install the EPC solenoid, bracket and bolt. ^ Tighten to 10 Nm (89 inch lbs.). 2. Inspect the lead frame for damage. ^ Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted. ^ If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, ^ Install a new lead frame. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 5921 3. Connect the molded lead frame to the solenoids. 1 Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 2 Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 3 Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 4 Connect the bulkhead interconnector by pressing it in place by hand and fully seating the connector in place. 4. Install the transmission fluid pan and filter. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Diagrams C2096 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Diagrams > Page 5925 Shifter A/T: Adjustments Selector Lever Indicator Adjustment 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 (1st gear), then rotate 2 detents counterclockwise ((D) position). 3. Hang a 3 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 3 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Button Shifter A/T: Service and Repair Selector Lever Button Selector Lever Button Selector Lever Button Removal 1. Place a small screwdriver in the slot at the bottom of the ring and slide the button assembly out and remove it from the knob. Installation 1. NOTE: The tool relief opening should be at the bottom of the button assembly. NOTE: It may be necessary to put pressure on the top of the selector lever knob bezel while installing the selector lever button. Install the selector lever button. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Button > Page 5928 Shifter A/T: Service and Repair Selector Lever Bezel Selector Lever Bezel Removal Selector Lever Bezel 1. Lift and remove the floor shift PRNDL trim plate. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Button > Page 5929 2. Place a small screwdriver in the slot at the bottom of the ring and slide the button assembly out and remove it from the knob. 3. Using a small flat-blade screwdriver, lift up on the shift knob bezel and remove the bezel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Button > Page 5930 4. Remove the 2 selector lever knob screws and remove the knob. 5. Remove the screws and the console finish panel. 6. Disconnect the 3 electrical connectors from the bezel. 7. Carefully release the retaining clips from the bezel and remove the bezel. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Button > Page 5931 1. Position the bezel on the selector lever and fasten the 3 tabs. 2. Connect the 3 electrical connectors. 3. Install the console finish panel and the 2 screws. 4. Install the selector lever knob and the 2 screws. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Button > Page 5932 5. NOTE: The selector lever button spring must be aligned on the locator on the underside of the selector lever knob bezel. Install the selector lever knob bezel. 6. NOTE: The tool relief opening should be at the bottom of the button assembly. NOTE: It may be necessary to put pressure on the top of the selector lever knob bezel while installing the selector lever button. Install the selector lever button. 7. Install the PRNDL trim plate. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Button > Page 5933 Shifter A/T: Service and Repair Selector Lever Knob Selector Lever Knob Removal Selector Lever Knob 1. Place a small screwdriver in the slot at the bottom of the ring and slide the button assembly out and remove it from the knob. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Button > Page 5934 2. Using a small flat-blade screwdriver, lift up on the shift knob bezel and remove the bezel. 3. Remove the 2 selector lever knob screws and remove the knob. Installation 1. Install the selector lever knob and the 2 screws. 2. NOTE: The selector lever button spring must be aligned on the locator on the underside of the selector lever knob bezel. Install the selector lever knob bezel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Button > Page 5935 3. NOTE: The tool relief opening should be at the bottom of the button assembly. NOTE: It may be necessary to put pressure on the top of the selector lever knob bezel while installing the selector lever button. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Button > Page 5936 Shifter A/T: Service and Repair Selector Lever - Column Shift Selector Lever - Column Shift Selector Lever - Column Shift Removal and Installation 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 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 shop manual to determine the 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 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Button > Page 5937 auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable. Wait at least one minute before proceeding with the procedure to allow the backup power supply to deplete its energy. 2. Remove the steering wheel. 3. Remove the 2 screws and the bottom steering column shroud. 4. Remove the screw and the top steering column shroud. 5. Disconnect the transmission control switch electrical connector. 6. CAUTION: Never reinstall the old gearshift lever pin. Remove the pin and the selector lever. Discard the selector lever pin. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Button > Page 5938 7. NOTE: A new gearshift lever pin must be installed whenever removed. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Button > Page 5939 Shifter A/T: Service and Repair Selector Lever - Floor Shift Selector Lever - Floor Shift Selector Lever - Floor Shift (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Button > Page 5940 Selector Lever - Floor Shift (Part 2) Removal and Installation 1. Lift and remove the floor shift PRNDL trim plate. 2. Place a small screwdriver in the slot at the bottom of the ring and slide the button assembly out and remove it from the knob. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Button > Page 5941 3. Using a small flat-blade screwdriver, lift up on the shift knob bezel and remove the bezel. 4. Remove the 2 shift lever knob screws and remove the knob. Slide the knob button out when the knob is removed. 5. Remove the spring from the top of the selector handle. 6. Position the window regulator control panel aside. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Button > Page 5942 7. Remove the screws and the console finish panel. 8. Remove the left side console access panel. 9. Disconnect the transmission shift cable from the transmission selector arm 10. Remove the transmission shift cable retaining clip from the floor shift mechanism through the console access. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Button > Page 5943 11. Remove the 4 nuts retaining the floor shift mechanism to the floor. ^ To install, tighten to 8 Nm (71 inch lbs.). 12. Remove the 3 bolts retaining the upper shift bracket to the console. ^ To install, tighten to 8 Nm (71 inch lbs.). 13. Remove the remaining bolt in the upper shift bracket from the console access panel side of the shift mechanism. ^ To install, tighten to 8 Nm (71 inch lbs.). 14. Disconnect the floor shift mechanism wire harness connector. 15. Remove the floor shift mechanism from the console. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Button > Page 5944 16. Disconnect the 3 electrical connectors from the light bar bezel. 17. Carefully release the retaining clips from the light bar bezel and remove the bezel. 18. The selector lever is serviced as an assembly. 19. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Cable and Bracket Adjustment Column Shift Shift Cable: Adjustments Cable and Bracket Adjustment Column Shift Cable and Bracket Adjustment Column Shift 1. Place the gearshift lever in the (D) position. ^ Place a 3 pound weight on the gearshift lever. 2. With the vehicle in NEUTRAL, position it on a hoist. 3. Disconnect the transmission shift cable from the manual control lever. 4. NOTE: Make sure the cable moves freely. 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 1st gear position. 2 Move the manual control lever 2 detents to the (D) position. 6. Connect the transmission shift cable to the manual control lever. 7. Lock the transmission shift cable lock tab. 8. Remove the 3 pound weight. 9. 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. ^ Readjust if necessary. 10. Vehicles equipped with a 4R70E/4R75E transmission, carry out the digital transmission range (TR) sensor adjustment. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Cable and Bracket Adjustment Column Shift > Page 5950 Shift Cable: Adjustments Cable and Bracket Adjustment Floor Shift Cable and Bracket Adjustment Floor Shift 1. With the vehicle in NEUTRAL, position the vehicle on a hoist. 2. Place the gearshift lever in the (D) position. 3. Disconnect the transmission shift cable from the manual control lever. 4. NOTE: Make sure the cable moves freely. Unlock the lock tab on the transmission shift cable. 5. Place the manual control lever in the (D) position. ^ Place the manual control lever in the 1st gear position. ^ Move the manual control lever 3 detents to the (D) position. 6. NOTE: Apply pressure to the selector lever cable end while connecting it to the manual lever to make sure the selector lever has not moved out of the (D) position. Connect the transmission shift cable to the manual control lever. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Cable and Bracket Adjustment Column Shift > Page 5951 7. Lock the transmission shift cable lock tab. 8. 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 through 5 must be repeated. ^ Readjust if necessary. 9. Vehicles equipped with a 4R70E/4R75E transmission, carry out the digital transmission range (TR) sensor adjustment. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable and Bracket Column Shift Shift Cable: Service and Repair Selector Lever Cable and Bracket Column Shift Selector Lever Cable and Bracket Column Shift Selector Lever Cable And Bracket - Column Shift Removal and Installation 1. Remove the instrument panel lower finish panel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable and Bracket Column Shift > Page 5954 2. NOTE: To prevent cable damage, do not apply force to the transmission shift cable assembly between the steering column transmission selector lever arm and the steering column bracket. Disconnect the transmission shift cable from the steering column. ^ Disconnect the transmission shift cable from the transmission selector lever arm and support. ^ Carefully lift the 2 locking tabs and disconnect the transmission shift cable from the steering column bracket. 3. Remove the cable retaining screw. 4. Push the rubber grommet and transmission shift cable through the floor panel. 5. With the vehicle in NEUTRAL, position it on a hoist. 6. NOTE: To prevent shift cable damage, do not apply force to the transmission shift cable between the manual control lever and the transmission shift cable bracket. Disconnect the transmission shift cable from the manual control lever. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable and Bracket Column Shift > Page 5955 7. Carefully pry behind the transmission shift cable lock tab to release the transmission shift cable from the bracket. 8. Remove the shift cable bracket from the transmission. ^ Remove the bolts. ^ To install, tighten to 25 Nm (18 ft. lbs.). ^ Remove the bracket. 9. Remove the cable from the cable route assist clip located at the transmission bell housing. 10. To install, reverse the removal procedure. CAUTION: Make sure the cable is inserted into the cable route assist clip. Failure to do so can result in exhaust contact. ^ Adjust the shift cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable and Bracket Column Shift > Page 5956 Shift Cable: Service and Repair Selector Lever Cable and Bracket Floor Shift Selector Lever Cable and Bracket Floor Shift Selector Lever Cable And Bracket- Floor Shift (Part 1) Selector Lever Cable And Bracket- Floor Shift (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable and Bracket Column Shift > Page 5957 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Lift and remove the floor shift PRNDL trim plate. 3. Position the window regulator control panel aside. 4. Remove the screws and the console finish panel. 5. Disconnect the transmission shift cable from the transmission selector arm Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Selector Lever Cable and Bracket Column Shift > Page 5958 6. Remove the left side console access panel. 7. Remove the transmission shift cable retaining clip from the floor shift mechanism through the console access panel. 8. Push the rubber grommet and transmission shift cable through the floor panel. 9. Remove the transmission shift cable from the automatic transmission. 10. Remove the shift cable bracket from the transmission. ^ Remove the bolts and the shift cable bracket. ^ To install, tighten to 48 Nm (35 ft. lbs.). 11. To install, reverse the removal procedure. ^ Adjust the shift cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor/Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5963 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5964 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5965 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5966 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5967 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5968 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5969 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5970 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5971 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5972 Throttle Position Sensor/Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5973 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5974 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5975 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5976 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5977 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5978 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5979 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 6HP26 Automatic Transmission Torque Converter: Description and Operation 6HP26 Automatic Transmission Torque Converter The torque converter is a 3-element unit containing a dual plate clutch. The clutch can be controlled and engaged in any gear 1st to 6th. Calibration parameters may be set to allow lock-up in a higher gear only. The clutch is applied by removing fluid pressure from one side of the plate. The torque converter transmits and multiplies torque. The torque converter includes the following 3 elements: ^ Impeller assembly ^ Turbine assembly ^ Reactor assembly The standard torque converter components operate as follows: Rotation of the converter housing and impeller set the fluid in motion. ^ The turbine reacts to the fluid motion from the impeller, transferring rotation to the geartrain through the input shaft. ^ The reactor redirects fluid going back into the impeller, allowing for torque multiplication. ^ Power is transmitted from the torque converter to the planetary gearsets and other components through the input shaft. Torque Converter Clutch The torque converter clutch is a device that reduces, slip in the torque converter and, therefore, helps to keep fuel consumption to a minimum. The torque converter clutch is engaged and released by the control system. Pressure at the torque converter clutch piston is determined by an electronic pressure control valve. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 6HP26 Automatic Transmission > Page 5984 Torque Converter: Description and Operation 4R70E/4R75E Automatic Transmission Torque Converter The torque converter transmits and multiplies torque. The torque converter is a 4-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. Torque Converter ^ Power is transmitted from the torque converter to the planetary gearsets and other components through the input shaft. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > 6HP26 Automatic Transmission Torque Converter: Testing and Inspection 6HP26 Automatic Transmission Torque Converter Diagnosis Prior to torque converter installation, all diagnostic procedures must be followed. This is to prevent the unnecessary installation of good torque converters. Only after a complete diagnostic evaluation can the decision be made to install a new torque converter. Begin with the normal diagnostic procedures as follows: 1. Preliminary inspection. 2. Know and understand the customer's concern. 3. Verify the condition carry out the torque converter operation test. 4. Carry out diagnostic procedures. ^ Carry out on-board diagnostics; refer to Diagnostics. See: Transmission Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/6HP26 Automatic Transmission - Repair all non-transmission related DTC's first. - Repair all transmission DTC's. - Rerun on-board diagnostic to Verify repair. ^ Carry out Stall Speed Test. See: Transmission Control Systems/Testing and Inspection/Component Tests and General Diagnostics/6HP26 Automatic Transmission/Non-Trouble Code Procedures/Stall Speed Test ^ Carry out Diagnostic Routines. Refer to Diagnosis By Symptom. See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/6HP26 Automatic Transmission/Diagnosis By Symptom - Use the Diagnosis by Symptom to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed, diagnose and repair as required before changing the torque converter. Torque Converter Operation Test This test verifies that the torque converter clutch control system and the torque converter are operating correctly. 1. Carry out Quick Test with diagnostic tool. Refer to Computers. Check for DTC's. 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 D6 position. 4. After normal operating temperature is reached, maintain a constant speed of about 80 km/h (50 mph) and tap the brake pedal with the left foot. 5. Engine rpm should increase when the brake pedal is tapped and decrease about 5 seconds after the pedal is released. If this does not occur, see Torque Converter Operation Concerns. Refer to Diagnosis By Symptom. See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/6HP26 Automatic Transmission/Diagnosis By Symptom 6. If the vehicle stalls in D6 or at idle with the vehicle at a stop, move the transmission range selector lever to the manual 1 position. If the vehicle stalls, see Torque Converter Operation Concerns. Refer to Diagnosis By Symptom. See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/6HP26 Automatic Transmission/Diagnosis By Symptom If the vehicle does not stall in D6, refer to Diagnosis By Symptom. See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/6HP26 Automatic Transmission/Diagnosis By Symptom NOTE: The following is a list of common vehicle concerns that have been misdiagnosed as torque converter clutch shudder. For diagnosis of the following items, refer to Computers. ^ Spark plugs - check for cracks, high resistance or broken insulators ^ Plug wires ^ Fuel injector - filter may be plugged ^ Fuel contamination - engine driveability concerns ^ EGR valve - valve may let in too much exhaust gas and cause engine to run lean ^ Vacuum leak - engine will not get correct air/fuel mixture ^ MAP/MAF sensor - incorrect air/fuel mixture ^ H02S sensor - too rich/lean air/fuel mixture ^ Fuel pressure - may be too low ^ Engine mounts - loose/damaged mounts can cause vibration concerns ^ Axle joints - check for vibration Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > 6HP26 Automatic Transmission > Page 5987 Torque Converter: Testing and Inspection 4R70E/4R75E Automatic Transmission Torque Converter Diagnosis Prior to installing new or remanufactured torque converters, all diagnostic procedures must be followed This is to prevent the unnecessary installation of new or remanufactured torque converters. Only after a complete diagnostic evaluation can the decision be made to install a new or remanufactured torque converter. Begin with the normal diagnostic procedures as follows: 1. Preliminary inspection. 2. Know and understand the customer's concern. 3. Verify the condition carry out the torque converter operation test. 4. Carry out diagnostic procedures. ^ Carry out on-board diagnostics; refer to Diagnostics. - Repair all non-transmission related DTC's first. - Repair all transmission DTC's. - Rerun on-board diagnostic to verify repair. ^ Carry out Line Pressure Test. See: Transmission Control Systems/Testing and Inspection/Component Tests and General Diagnostics/4R70E/4R75E - Automatic Transmission/Non-Trouble Code Procedures/Line Pressure Test ^ Carry out Stall Speed Test. See: Transmission Control Systems/Testing and Inspection/Component Tests and General Diagnostics/4R70E/4R75E - Automatic Transmission/Non-Trouble Code Procedures/Stall Speed Test ^ Carry out Diagnostic Routines. See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/4R70E/4R75E/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 changing the torque converter. Torque Converter Operation Test This test verifies that the torque converter clutch control system and the torque converter are operating correctly. 1. Carry out Quick Test with diagnostic tool. For additional information, refer to Computers and control systems. 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 5 seconds after pedal is released. If this does not occur, see torque converter operation concerns. For additional information, refer to Diagnosis By Symptom. See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/4R70E/4R75E/Diagnosis By Symptom 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, see torque converter operation concerns. For additional information, refer to Diagnosis By Symptom. See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/4R70E/4R75E/Diagnosis By Symptom If the vehicle does not stall in (D), refer to Diagnosis By Symptom. See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/4R70E/4R75E/Diagnosis By Symptom 7. If the vehicle exhibits a vibration during the road test complete the Road Test Evaluation Form. This form 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 shudder. For diagnosis of the following items refer to Computers. ^ Spark plugs - check for cracks, high resistance or broken insulators. ^ Plug wires. ^ Fuel injector - filter may be plugged. ^ Fuel contamination - engine runs poor. ^ EGR valve - valve may let in too much exhaust gas and cause engine to run lean. ^ Vacuum leak - engine will not get correct air/fuel mixture. ^ MAP/MAF sensor - incorrect air/fuel mixture. H02S sensor - too rich/lean air/fuel mixture. - Fuel pressure - may be too low. - Engine mounts - loose/damaged mounts can cause vibration concerns. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > 6HP26 Automatic Transmission > Page 5988 Torque Converter Toad Evaluation Forum (Part 1) Torque Converter Toad Evaluation Forum (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > 6HP26 Automatic Transmission > Page 5989 - Axle joints - check for vibration. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch: > 09-20-14 > Oct > 09 > A/T - Uncommanded TCC Lock Up On 1-2 Upshift Torque Converter Clutch: Customer Interest A/T - Uncommanded TCC Lock Up On 1-2 Upshift TSB 09-20-14 10/19/09 UN-COMMANDED TCC APPLY ON THE 1-2 SHIFT CAUSING PERCEPTION OF HESITATION AND/OR LACK OF POWER DURING SHIFT FORD: 2005-2010 Crown Victoria 2005-2006 Expedition 2005-2010 E-150, E-250, E-350, F-150 LINCOLN: 2005-2010 Town Car 2006-2008 Mark LT MERCURY: 2005-2010 Grand Marquis This article supersedes TSB 6-22-7 to update the Issue Statement, vehicle model years and model line covered. ISSUE Some 2005-2010 vehicles equipped with a 4R70/75E-W transmission may experience an un-commanded torque converter clutch (TCC) apply or TCC partial apply immediately after the 1-2 shift. This may result in the perception that the vehicle lacks power or that the transmission is up-shifting too early. Additional symptoms of uncommanded TCC apply when coming to a stop (before the 2-1 downshift is commanded), are engine stalling or lugging when engaging manual 2nd while at a stop and code P1742 may be present in continuous memory. However, the vehicle should operate normally in park, reverse, neutral and manual 1st gear. ACTION Follow the Service Procedure for verification and repair. SERVICE PROCEDURE 1. Monitor (TCC %) solenoid command state - duty cycle and (TC SLIP ACT) torque converter clutch slippage - RPM, while in 2nd, 3rd or 4th gear with a TCC % reading 0. a. If TCC % = 0 and TC SLIP ACT = less than 20 RPM then inspect the number 7 check ball in the main control valve body for damage. Replace as required following the appropriate Workshop Manual (WSM) under Disassembly and Assembly of Subassemblies - Main Control Valve Body. (Figure 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch: > 09-20-14 > Oct > 09 > A/T - Uncommanded TCC Lock Up On 1-2 Upshift > Page 5998 NOTE THIS PROCEDURE IS PERFORMED IN 2ND GEAR AUTO (NOT MANUAL 2). MONITOR (TC SLIP ACT) AFTER THE POWERTRAIN CONTROL MODULE (PCM) COMMANDS 2ND GEAR AND BEFORE THE VEHICLE SPEED SENSOR (VSS) READS 35 MPH (56 KM/H). b. If you receive any other reading, this procedure does not apply; follow normal diagnostic procedures as outlined in the appropriate WSM. NOTE IT IS NORMAL FOR THE PCM TO COMMAND 4TH GEAR AT SPEEDS AS LOW AS 19 MPH (30 KM/H) WITH LIGHT ACCELERATION WHEN THE THROTTLE POSITION IS LESS THEN 20%. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092014A 2005-2010 Crown Victoria, 2.3 Hrs. Grand Marquis, Town Car, Econoline 150/250/350, 2005-2006 Expedition: Includes Time To Perform The Diagnosis Outlined In This Article And Repair (Do Not Use With Any Other Labor Operations) 092014A 2005-2010 F-150, 2.2 Hrs. 2006-2008 Mark LT: Includes Time To Perform The Diagnosis Outlined In This Article And Repair (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7E195 01 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch: > 09-20-14 > Oct > 09 > A/T - Uncommanded TCC Lock Up On 1-2 Upshift Torque Converter Clutch: All Technical Service Bulletins A/T - Uncommanded TCC Lock Up On 1-2 Upshift TSB 09-20-14 10/19/09 UN-COMMANDED TCC APPLY ON THE 1-2 SHIFT CAUSING PERCEPTION OF HESITATION AND/OR LACK OF POWER DURING SHIFT FORD: 2005-2010 Crown Victoria 2005-2006 Expedition 2005-2010 E-150, E-250, E-350, F-150 LINCOLN: 2005-2010 Town Car 2006-2008 Mark LT MERCURY: 2005-2010 Grand Marquis This article supersedes TSB 6-22-7 to update the Issue Statement, vehicle model years and model line covered. ISSUE Some 2005-2010 vehicles equipped with a 4R70/75E-W transmission may experience an un-commanded torque converter clutch (TCC) apply or TCC partial apply immediately after the 1-2 shift. This may result in the perception that the vehicle lacks power or that the transmission is up-shifting too early. Additional symptoms of uncommanded TCC apply when coming to a stop (before the 2-1 downshift is commanded), are engine stalling or lugging when engaging manual 2nd while at a stop and code P1742 may be present in continuous memory. However, the vehicle should operate normally in park, reverse, neutral and manual 1st gear. ACTION Follow the Service Procedure for verification and repair. SERVICE PROCEDURE 1. Monitor (TCC %) solenoid command state - duty cycle and (TC SLIP ACT) torque converter clutch slippage - RPM, while in 2nd, 3rd or 4th gear with a TCC % reading 0. a. If TCC % = 0 and TC SLIP ACT = less than 20 RPM then inspect the number 7 check ball in the main control valve body for damage. Replace as required following the appropriate Workshop Manual (WSM) under Disassembly and Assembly of Subassemblies - Main Control Valve Body. (Figure 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch: > 09-20-14 > Oct > 09 > A/T - Uncommanded TCC Lock Up On 1-2 Upshift > Page 6004 NOTE THIS PROCEDURE IS PERFORMED IN 2ND GEAR AUTO (NOT MANUAL 2). MONITOR (TC SLIP ACT) AFTER THE POWERTRAIN CONTROL MODULE (PCM) COMMANDS 2ND GEAR AND BEFORE THE VEHICLE SPEED SENSOR (VSS) READS 35 MPH (56 KM/H). b. If you receive any other reading, this procedure does not apply; follow normal diagnostic procedures as outlined in the appropriate WSM. NOTE IT IS NORMAL FOR THE PCM TO COMMAND 4TH GEAR AT SPEEDS AS LOW AS 19 MPH (30 KM/H) WITH LIGHT ACCELERATION WHEN THE THROTTLE POSITION IS LESS THEN 20%. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092014A 2005-2010 Crown Victoria, 2.3 Hrs. Grand Marquis, Town Car, Econoline 150/250/350, 2005-2006 Expedition: Includes Time To Perform The Diagnosis Outlined In This Article And Repair (Do Not Use With Any Other Labor Operations) 092014A 2005-2010 F-150, 2.2 Hrs. 2006-2008 Mark LT: Includes Time To Perform The Diagnosis Outlined In This Article And Repair (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7E195 01 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6009 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6010 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6011 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6012 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6013 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6014 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6015 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6016 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6017 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6018 Torque Converter Clutch Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6019 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6020 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6021 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6022 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6023 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6024 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6025 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6026 Solenoid Operation Chart Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6027 Torque Converter Clutch Solenoid: Testing and Inspection 4R70E/4R75E Automatic Transmission Pinpoint Tests - OSC Equipped Vehicles Special Tools Any time an electrical connector or solenoid body is disconnected, inspect the connector for pin condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install a new connector or component as required. Shift Solenoids Pre-Diagnosis Use the following shift solenoid operation information when carrying out Pinpoint Test A. See: Transmission Control Systems/Testing and Inspection/Pinpoint Tests/Pinpoint Tests/Test A: Shift and Torque Converter Clutch Solenoids Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6028 Solenoid Operation Chart Shift Solenoid Failure Mode Chart "Always off" (Part 1) Shift Solenoid Failure Mode Chart "Always off" (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6029 Shift Solenoid Failure Mode Chart "Always off" (Part 3) Failed off due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck off. Shift Solenoid Failure Mode Chart "Always On" (Part 1) Shift Solenoid Failure Mode Chart "Always On" (Part 2) Shift Solenoid Failure Mode Chart "Always On" (Part 3) Failed on due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck on. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6030 Torque Converter Clutch Solenoid: Service and Repair 4R70E/4R75E Electronic Pressure Control (EPC) Solenoid Special Tools Removal CAUTION: Do not pull on the molded 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. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid and remove the transmission fluid pan and filter. 3. 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 interconnector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6031 4. Remove the EPC solenoid. Installation 1. NOTE: Lubricate the EPC solenoid O-rings with clean automatic transmission fluid. Install the EPC solenoid, bracket and bolt. ^ Tighten to 10 Nm (89 inch lbs.). 2. Inspect the lead frame for damage. ^ Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted. ^ If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, ^ Install a new lead frame. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6032 3. Connect the molded lead frame to the solenoids. 1 Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 2 Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 3 Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 4 Connect the bulkhead interconnector by pressing it in place by hand and fully seating the connector in place. 4. Install the transmission fluid pan and filter. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Cover > Component Information > Service and Repair Torque Converter Cover: Service and Repair 6HP26 Automatic Transmission Transmission Fluid Cooler Backflushing and Cleaning Material CAUTION: When internal damage occurs in the transmission, metal particles and clutch plate material can travel into the torque converter and the transmission fluid cooler. These contaminates are a major cause of recurring transmission concerns. To prevent further concerns, remove these contaminates from the cooler lines and install a new cooler before placing the transmission in use. 1. Install a new transmission fluid cooler if any fluid leak are indicated or a major metallic failure is indicated. 2. Using a suitable torque converter/fluid cooler cleaner, flush the fluid cooler and lines. 3. NOTE: Rubber hoses must be attached to the ends of the fluid cooler tubes, to aid in connecting them to the cleaner. Connect the cleaner pressure and return lines appropriately. 1 Connect the pressure line to the fluid cooler inlet tube. 2 Connect the return line to the fluid cooler outlet tube. 3 Place the outlet end of the return line in the fluid tank reservoir. 4. NOTE: Cycling the fluid pump on and off will help dislodge contaminants in the cooler system. Switch the fluid pumps on. Allow the fluid to circulate a minimum of 5 minutes. 5. Switch the fluid pump off. 6. Disconnect the cleaner pressure line at the fluid cooler tube. 7. Using compressed air, blow through the fluid cooler inlet tube until all fluid is removed. 8. Remove the rubber hoses from the fluid cooler tubes. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > General Specifications General Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > General Specifications > Page 6040 Torque Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Page 6041 Transmission Cooler: Locations 4R70E, 4R75E Transmissions With Auxiliary Transmission Fluid Cooler 4R70E, 4R75E Transmissions Without Auxiliary Transmission Fluid Cooler Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Page 6042 6HP26 Transmission With Auxiliary Transmission Fluid Cooler Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission Transmission Cooler: Service and Repair 6HP26 Automatic Transmission Transmission Fluid Cooler Backflushing and Cleaning 6HP26 Automatic Transmission Transmission Fluid Cooler Backflushing and Cleaning Material CAUTION: When internal damage occurs in the transmission, metal particles and clutch plate material can travel into the torque converter and the transmission fluid cooler. These contaminates are a major cause of recurring transmission concerns. To prevent further concerns, remove these contaminates from the cooler lines and install a new cooler before placing the transmission in use. 1. Install a new transmission fluid cooler if any fluid leak are indicated or a major metallic failure is indicated. 2. Using a suitable torque converter/fluid cooler cleaner, flush the fluid cooler and lines. 3. NOTE: Rubber hoses must be attached to the ends of the fluid cooler tubes, to aid in connecting them to the cleaner. Connect the cleaner pressure and return lines appropriately. 1 Connect the pressure line to the fluid cooler inlet tube. 2 Connect the return line to the fluid cooler outlet tube. 3 Place the outlet end of the return line in the fluid tank reservoir. 4. NOTE: Cycling the fluid pump on and off will help dislodge contaminants in the cooler system. Switch the fluid pumps on. Allow the fluid to circulate a minimum of 5 minutes. 5. Switch the fluid pump off. 6. Disconnect the cleaner pressure line at the fluid cooler tube. 7. Using compressed air, blow through the fluid cooler inlet tube until all fluid is removed. 8. Remove the rubber hoses from the fluid cooler tubes. Auxiliary Transmission Fluid Cooler Auxiliary Transmission Fluid Cooler Special Tools Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 6045 Materials Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Using the special tool, disconnect the fluid cooler tube from the auxiliary transmission fluid cooler. 3. Using the special tool, disconnect the fluid cooler tube from the auxiliary transmission fluid cooler. 4. Remove the pushpin retainers and remove the air deflector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 6046 5. Remove the 3 bolts and remove the auxiliary transmission fluid cooler. Installation 1. Install the auxiliary transmission fluid cooler and install the 3 bolts. ^ Tighten to 20 Nm (15 ft. lbs.). 2. Position the air deflector and install the pushpin retainers. 3. Connect the fluid cooler tubes into the auxiliary transmission fluid cooler. 4. With the vehicle idling (600 - 750 rpm) in PARK, and the transmission temperature at 30°C - 50°C (86°F - 122°F), check and adjust the transmission fluid level. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 6047 5. CAUTION: The fluid fill plug located on the side of the transmission is near the exhaust system. The exhaust will be extremely hot during this procedure. Use care when working near the exhaust and the heat shields. Remove the fluid fill plug located on the RH rear side of the case near the transmission electrical connector. 6. CAUTION: The use of any other transmission fluid can result in the transmission failing to operate in a normal manner or transmission failure. CAUTION: The fluid fill plug located on the side of the transmission is near the exhaust system. The exhaust will be extremely hot during this procedure. Use care when working near the exhaust and the heat shields. Fill the transmission. ^ Add clean automatic transmission fluid to the transmission through the fluid fill hole. ^ Stop when the fluid runs out of the bottom of the hole. 7. CAUTION: The fluid fill plug located on the side of the transmission is near the exhaust system. The exhaust will be extremely hot during this procedure. Use care when working near the exhaust and the heat shields. Install the fluid fill plug. ^ Tighten to 35 Nm (26 ft. lbs.). 8. Move the transmission range selector lever through all the gear ranges, checking for engagements. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 6048 9. CAUTION: The fluid fill plug located on the side of the transmission is near the exhaust system. The exhaust will be extremely hot during this procedure. Use care when working near the exhaust and the heat shields. If more fluid is needed, start the engine. ^ Remove the fluid fill plug on the side of the case, fill with clean automatic transmission fluid until fluid just starts to dribble out of the hole. ^ Install the fill plug. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 6049 Transmission Cooler: Service and Repair 4R70E/4R75E Automatic Transmission Transmission Fluid Cooler Backflushing and Cleaning Transmission Fluid Cooler Backflushing and Cleaning Material 1. CAUTION: Do not use any supplemental transmission fluid additives or cleaning agents. The use of these products could cause internal transmission components to fail; this will effect the operation of the transmission. Conduct backflushing with a suitable torque converter/fluid cooler cleaner. Test your equipment to make sure that a vigorous fluid flow is present before proceeding. Install a new filter in the flush equipment if flow is weak or contaminated. 2. If equipped, remove and discard the transmission fluid in-line filter. 3. Remove the transmission fluid cooler bypass valve and install rubber hoses in its place. 4. To aid in attaching the cleaner to the transmission steel cooler lines, connect 2 additional rubber hoses to the transmission end of the steel transmission cooler lines as described below. ^ Connect the cleaner tank pressure line to the steel transmission cooler return line (longest line). ^ Connect a tank return hose to the steel transmission cooler pressure line (shorter line). Place the outlet end of this hose in the tank reservoir. 5. Turn on the pump and allow the fluid to circulate a minimum of 5 minutes (cycling switch on and off will help dislodge contaminants in cooler system). 6. Switch off the pump and disconnect the pressure hose from the transmission cooler return line. 7. Use compressed air to blow out the cooler(s) and lines (blow air into the transmission cooler return line) until all fluid is removed. 8. Remove the rubber return hose from the remaining steel cooler line. 9. Remove the rubber hoses and reinstall the transmission fluid cooler bypass valve. Auxiliary Transmission Fluid Cooler Auxiliary Transmission Fluid Cooler - 4R70E,4R75E Special Tools Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 6050 Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Using the special tool, disconnect the fluid cooler tube from the auxiliary transmission fluid cooler. 3. Using the special tool, disconnect the fluid cooler tube from the auxiliary transmission fluid cooler. 4. Remove the pushpin retainers and remove the air deflector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > 6HP26 Automatic Transmission > Page 6051 5. Remove the 3 bolts and remove the auxiliary transmission fluid cooler. Installation 1. Install the auxiliary transmission fluid cooler and install the 3 bolts. ^ Tighten to 20 Nm (15 ft. lbs.). 2. Position the air deflector and install the pushpin retainers. 3. Connect the fluid cooler tubes into the auxiliary transmission fluid cooler. 4. Fill the transmission with the specified type and quantity of transmission fluid. 5. Check for leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation TRANSMISSION CONTROL INDICATOR LAMP (TCIL) The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Mode Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6059 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6060 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6061 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6062 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6063 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6064 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6065 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6066 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6067 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6068 Transmission Mode Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6069 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6070 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6071 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6072 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6073 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6074 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6075 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 6076 Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH (TCS) Typical Transmission Control Switch (TCS) Typical Transmission Control Switch (TCS) The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature, the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage overdrive. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mount: > 06-5-1 > Mar > 06 > Engine Controls - Cold Start Rough Idle Condition Transmission Mount: Customer Interest Engine Controls - Cold Start Rough Idle Condition TSB 06-5-1 03/20/06 COLD START ROUGH IDLE EXPEDITION 4X2 ONLY FORD: 2005-2006 Expedition ISSUE Some 2005-2006 Expedition 4x2 vehicles may exhibit an idle vibration during cold start at 1400 RPM, that lasts for a few seconds. The symptom is perceived as shaking of the entire vehicle when the engine is first started after being off for an extended period of time in warm weather in excess of a few hours, such as overnight, with ambient temperatures greater than 60° F (16° C). The issue is not typically accompanied by unusual engine or fan noise. It is independent of air conditioning compressor engagement (bumps, bangs, or thumps) and air suspension pump operation (audible hum or buzz accompanied by an associated vibration). ACTION Use the following Service Procedure to resolve the concern. SERVICE PROCEDURE 1. Using normal Workshop Manual diagnostics: a. Verify the integrity of the fuel system (fuel injectors, fuel pump, fuel quality) and repair as necessary. b. Check ignition system (spark plugs, ignition coils), mechanical engine operation, and repair as necessary. 2. Check the engine assembly exhaust mounting systems for ground-outs, damage, and repair as necessary. 3. If no concerns are found or cold start symptoms continue, reprogram the powertrain control module (PCM) to the latest calibration using WDS release B41.10 and higher or B42.1 and higher. This new calibration is not included in the B42 CD. Calibration files may also be obtained at the website. NOTE COLD ENGINE IDLE SPEED WILL DROP TO 1250 RPM AND WARM DRIVE IDLE SPEED WILL INCREASE TO 650 RPM. THIS CALIBRATION IS MATCHED TO THE SERVICE ENGINE/TRANSMISSION MOUNTS LISTED IN THIS TSB. DO NOT RE-INSTALL THE ORIGINAL ENGINE/TRANSMISSION MOUNTS AFTER PERFORMING THIS RECALIBRATION. 4. Replace the left hand and right hand engine mounts. Refer to the Workshop Manual, Section 303-01 - Engine Support Insulators 5. Replace the transmission mount. Refer to Workshop Manual, Section 307-01B - Transmission Insulator & Retainer Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 060501A 2005 Expedition 4X2: 3.7 Hrs. Replace Both Engine Mounts, and Transmission Mount, Reprogram The Powertrain Control Module (Do Not Use With 6038A, 6068A, 12650D, 12650D84, 050415A, Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mount: > 06-5-1 > Mar > 06 > Engine Controls - Cold Start Rough Idle Condition > Page 6085 052301A) 060501B 2006 Expedition 4X2: 3.6 Hrs. Replace Both Engine Mounts, and Transmission Mount, Reprogram The Powertrain Control Module (Do Not Use With 6038A, 6068A, 12650D, 12650D84, 050415A, 052301A) MT060501 Claim Additional Labor Actual Required As Actual Time Time Or Use SLTS Operation If Available DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mount: > 06-5-1 > Mar > 06 > Engine Controls - Cold Start Rough Idle Condition Transmission Mount: All Technical Service Bulletins Engine Controls - Cold Start Rough Idle Condition TSB 06-5-1 03/20/06 COLD START ROUGH IDLE EXPEDITION 4X2 ONLY FORD: 2005-2006 Expedition ISSUE Some 2005-2006 Expedition 4x2 vehicles may exhibit an idle vibration during cold start at 1400 RPM, that lasts for a few seconds. The symptom is perceived as shaking of the entire vehicle when the engine is first started after being off for an extended period of time in warm weather in excess of a few hours, such as overnight, with ambient temperatures greater than 60° F (16° C). The issue is not typically accompanied by unusual engine or fan noise. It is independent of air conditioning compressor engagement (bumps, bangs, or thumps) and air suspension pump operation (audible hum or buzz accompanied by an associated vibration). ACTION Use the following Service Procedure to resolve the concern. SERVICE PROCEDURE 1. Using normal Workshop Manual diagnostics: a. Verify the integrity of the fuel system (fuel injectors, fuel pump, fuel quality) and repair as necessary. b. Check ignition system (spark plugs, ignition coils), mechanical engine operation, and repair as necessary. 2. Check the engine assembly exhaust mounting systems for ground-outs, damage, and repair as necessary. 3. If no concerns are found or cold start symptoms continue, reprogram the powertrain control module (PCM) to the latest calibration using WDS release B41.10 and higher or B42.1 and higher. This new calibration is not included in the B42 CD. Calibration files may also be obtained at the website. NOTE COLD ENGINE IDLE SPEED WILL DROP TO 1250 RPM AND WARM DRIVE IDLE SPEED WILL INCREASE TO 650 RPM. THIS CALIBRATION IS MATCHED TO THE SERVICE ENGINE/TRANSMISSION MOUNTS LISTED IN THIS TSB. DO NOT RE-INSTALL THE ORIGINAL ENGINE/TRANSMISSION MOUNTS AFTER PERFORMING THIS RECALIBRATION. 4. Replace the left hand and right hand engine mounts. Refer to the Workshop Manual, Section 303-01 - Engine Support Insulators 5. Replace the transmission mount. Refer to Workshop Manual, Section 307-01B - Transmission Insulator & Retainer Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 060501A 2005 Expedition 4X2: 3.7 Hrs. Replace Both Engine Mounts, and Transmission Mount, Reprogram The Powertrain Control Module (Do Not Use With 6038A, 6068A, 12650D, 12650D84, 050415A, Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mount: > 06-5-1 > Mar > 06 > Engine Controls - Cold Start Rough Idle Condition > Page 6091 052301A) 060501B 2006 Expedition 4X2: 3.6 Hrs. Replace Both Engine Mounts, and Transmission Mount, Reprogram The Powertrain Control Module (Do Not Use With 6038A, 6068A, 12650D, 12650D84, 050415A, 052301A) MT060501 Claim Additional Labor Actual Required As Actual Time Time Or Use SLTS Operation If Available DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Page 6092 Transmission Mount: Service and Repair 4R70E/4R75E Automatic Transmission Transmission Insulator and Retainer Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the rear transmission support nuts. 3. Install a suitable transmission Jack. 4. Slightly raise the rear of the transmission and remove the bolts. Remove the rear transmission mount. Installation 1. Install the rear transmission mount and the bolts. ^ Tighten to 80 Nm (59 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Page 6093 2. Lower the transmission onto the crossmember and install the nuts. ^ Tighten to 90 Nm (66 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 6097 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6100 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6101 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6102 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6103 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6104 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6105 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6106 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6107 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6108 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6109 Transmission Position Switch/Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6110 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6111 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6112 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6113 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6114 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6115 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6116 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6117 C167 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 6118 Transmission Position Switch/Sensor: Adjustments 4R70E/4R75E Transmission Range (TR) Sensor Adjustment Special Tools 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual lever shift control cable. 3. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control lever nut. 2 Remove the manual control lever. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 6119 4. Loosen the digital transmission range (TR) sensor bolts. 5. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 6. CAUTION: Tightening one bolt before tightening the other may cause the sensor to bind or become damaged. Using the special tool, align the digital TR sensor and tighten the bolts in an alternating sequence. ^ Tighten to 9 Nm (80 inch lbs.). 7. Install the manual control lever. ^ Position the manual control lever. 2 Install a new manual lever shaft outer nut. ^ Tighten to 33 Nm (24 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 6120 8. With the manual lever in overdrive connect the shift lever control cable. 9. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 6121 Transmission Position Switch/Sensor: Service and Repair 4R70E/4R75E Automatic Transmission Digital Transmission Range (TR) Sensor Special Tools Removal NOTE: Manual shift lever must be in the NEUTRAL position. 1. With the vehicle in NEUTRAL, position it on a hoist. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 6122 2. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual control lever shift control cable. 3. Disconnect the digital TR electrical connector. 4. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control nut. 2 Remove the manual control lever. 5. Remove the digital TR sensor bolts and the digital TR sensor. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 6123 1. Install the digital TR sensor and loosely install the bolts. 2. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 3. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. Tighten the digital TR sensor bolts. ^ Tighten to 9 Nm (80 inch lbs.). 4. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual control lever nut. ^ Tighten to 33 Nm (24 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 6124 5. Connect the digital TR sensor electrical connector. 6. Connect the shift cable end to the manual lever with the lever in the (D) position. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Locations > 6HP26 Automatic Transmission Air Pressure Test Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Locations > 6HP26 Automatic Transmission > Page 6129 Transmission Air Test Plate Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Turbine Shaft Speed (TSS) Sensor > Page 6134 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Turbine Shaft Speed (TSS) Sensor > Page 6135 Transmission Speed Sensor: Locations Output Shaft Speed (OSS) Sensor View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Turbine Shaft Speed (TSS) Sensor > Page 6136 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Speed Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6139 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6140 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6141 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6142 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6143 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6144 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6145 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6146 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6147 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6148 Transmission Speed Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6149 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6150 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6151 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6152 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6153 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6154 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6155 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6156 Transmission Speed Sensor: Connector Views C193 C143 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 6157 Transmission Speed Sensor: Service and Repair 4R70E/4R75E Automatic Transmission Speed Sensors Speed Sensors NOTE: Only remove the affected sensor. Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist, OSS sensor 2. Disconnect the output shaft speed (OSS) sensor electrical connector. 3. Remove the OSS sensor bolt. 4. Remove the OSS sensor. TSS sensor 5. Disconnect the turbine shaft speed (TSS) sensor electrical connector. 6. Remove the TSS sensor bolt. 7. Remove the TSS sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 6158 Installation TSS sensor 1. Lubricate the O-ring seal and install the TSS sensor. 2. Install the TSS sensor bolt. ^ Tighten to 11 Nm (8 ft. lbs.). 3. Connect the TSS sensor electrical connector. OSS sensor 4. Lubricate the O-ring seal and install the OSS sensor. 5. Install the OSS sensor bolt. ^ Tighten to 12 Nm (9 ft. lbs.). 6. Connect the OSS sensor electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 09-20-14 > Oct > 09 > A/T Uncommanded TCC Lock Up On 1-2 Upshift Valve Body: Customer Interest A/T - Uncommanded TCC Lock Up On 1-2 Upshift TSB 09-20-14 10/19/09 UN-COMMANDED TCC APPLY ON THE 1-2 SHIFT CAUSING PERCEPTION OF HESITATION AND/OR LACK OF POWER DURING SHIFT FORD: 2005-2010 Crown Victoria 2005-2006 Expedition 2005-2010 E-150, E-250, E-350, F-150 LINCOLN: 2005-2010 Town Car 2006-2008 Mark LT MERCURY: 2005-2010 Grand Marquis This article supersedes TSB 6-22-7 to update the Issue Statement, vehicle model years and model line covered. ISSUE Some 2005-2010 vehicles equipped with a 4R70/75E-W transmission may experience an un-commanded torque converter clutch (TCC) apply or TCC partial apply immediately after the 1-2 shift. This may result in the perception that the vehicle lacks power or that the transmission is up-shifting too early. Additional symptoms of uncommanded TCC apply when coming to a stop (before the 2-1 downshift is commanded), are engine stalling or lugging when engaging manual 2nd while at a stop and code P1742 may be present in continuous memory. However, the vehicle should operate normally in park, reverse, neutral and manual 1st gear. ACTION Follow the Service Procedure for verification and repair. SERVICE PROCEDURE 1. Monitor (TCC %) solenoid command state - duty cycle and (TC SLIP ACT) torque converter clutch slippage - RPM, while in 2nd, 3rd or 4th gear with a TCC % reading 0. a. If TCC % = 0 and TC SLIP ACT = less than 20 RPM then inspect the number 7 check ball in the main control valve body for damage. Replace as required following the appropriate Workshop Manual (WSM) under Disassembly and Assembly of Subassemblies - Main Control Valve Body. (Figure 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 09-20-14 > Oct > 09 > A/T Uncommanded TCC Lock Up On 1-2 Upshift > Page 6167 NOTE THIS PROCEDURE IS PERFORMED IN 2ND GEAR AUTO (NOT MANUAL 2). MONITOR (TC SLIP ACT) AFTER THE POWERTRAIN CONTROL MODULE (PCM) COMMANDS 2ND GEAR AND BEFORE THE VEHICLE SPEED SENSOR (VSS) READS 35 MPH (56 KM/H). b. If you receive any other reading, this procedure does not apply; follow normal diagnostic procedures as outlined in the appropriate WSM. NOTE IT IS NORMAL FOR THE PCM TO COMMAND 4TH GEAR AT SPEEDS AS LOW AS 19 MPH (30 KM/H) WITH LIGHT ACCELERATION WHEN THE THROTTLE POSITION IS LESS THEN 20%. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092014A 2005-2010 Crown Victoria, 2.3 Hrs. Grand Marquis, Town Car, Econoline 150/250/350, 2005-2006 Expedition: Includes Time To Perform The Diagnosis Outlined In This Article And Repair (Do Not Use With Any Other Labor Operations) 092014A 2005-2010 F-150, 2.2 Hrs. 2006-2008 Mark LT: Includes Time To Perform The Diagnosis Outlined In This Article And Repair (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7E195 01 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 09-20-14 > Oct > 09 > A/T - Uncommanded TCC Lock Up On 1-2 Upshift Valve Body: All Technical Service Bulletins A/T - Uncommanded TCC Lock Up On 1-2 Upshift TSB 09-20-14 10/19/09 UN-COMMANDED TCC APPLY ON THE 1-2 SHIFT CAUSING PERCEPTION OF HESITATION AND/OR LACK OF POWER DURING SHIFT FORD: 2005-2010 Crown Victoria 2005-2006 Expedition 2005-2010 E-150, E-250, E-350, F-150 LINCOLN: 2005-2010 Town Car 2006-2008 Mark LT MERCURY: 2005-2010 Grand Marquis This article supersedes TSB 6-22-7 to update the Issue Statement, vehicle model years and model line covered. ISSUE Some 2005-2010 vehicles equipped with a 4R70/75E-W transmission may experience an un-commanded torque converter clutch (TCC) apply or TCC partial apply immediately after the 1-2 shift. This may result in the perception that the vehicle lacks power or that the transmission is up-shifting too early. Additional symptoms of uncommanded TCC apply when coming to a stop (before the 2-1 downshift is commanded), are engine stalling or lugging when engaging manual 2nd while at a stop and code P1742 may be present in continuous memory. However, the vehicle should operate normally in park, reverse, neutral and manual 1st gear. ACTION Follow the Service Procedure for verification and repair. SERVICE PROCEDURE 1. Monitor (TCC %) solenoid command state - duty cycle and (TC SLIP ACT) torque converter clutch slippage - RPM, while in 2nd, 3rd or 4th gear with a TCC % reading 0. a. If TCC % = 0 and TC SLIP ACT = less than 20 RPM then inspect the number 7 check ball in the main control valve body for damage. Replace as required following the appropriate Workshop Manual (WSM) under Disassembly and Assembly of Subassemblies - Main Control Valve Body. (Figure 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 09-20-14 > Oct > 09 > A/T - Uncommanded TCC Lock Up On 1-2 Upshift > Page 6173 NOTE THIS PROCEDURE IS PERFORMED IN 2ND GEAR AUTO (NOT MANUAL 2). MONITOR (TC SLIP ACT) AFTER THE POWERTRAIN CONTROL MODULE (PCM) COMMANDS 2ND GEAR AND BEFORE THE VEHICLE SPEED SENSOR (VSS) READS 35 MPH (56 KM/H). b. If you receive any other reading, this procedure does not apply; follow normal diagnostic procedures as outlined in the appropriate WSM. NOTE IT IS NORMAL FOR THE PCM TO COMMAND 4TH GEAR AT SPEEDS AS LOW AS 19 MPH (30 KM/H) WITH LIGHT ACCELERATION WHEN THE THROTTLE POSITION IS LESS THEN 20%. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092014A 2005-2010 Crown Victoria, 2.3 Hrs. Grand Marquis, Town Car, Econoline 150/250/350, 2005-2006 Expedition: Includes Time To Perform The Diagnosis Outlined In This Article And Repair (Do Not Use With Any Other Labor Operations) 092014A 2005-2010 F-150, 2.2 Hrs. 2006-2008 Mark LT: Includes Time To Perform The Diagnosis Outlined In This Article And Repair (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7E195 01 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 6174 Valve Body: Locations Check Ball Location Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 6175 Main Control Valve Body Disassembled View (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 6176 Main Control Valve Body Disassembled View (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 6177 Main Control Valve Body Disassembled View (Part 3) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 6178 Valve Body: Diagrams Main Control Valve Body Disassembled View (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 6179 Main Control Valve Body Disassembled View (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 6180 Main Control Valve Body Disassembled View (Part 3) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70E/4R75E Valve Body: Service and Repair 4R70E/4R75E Electronic Pressure Control (EPC) Solenoid Electronic Pressure Control (EPC) Solenoid Special Tools Removal CAUTION: Do not pull on the molded 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. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid and remove the transmission fluid pan and filter. 3. 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 interconnector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70E/4R75E > Page 6183 4. Remove the EPC solenoid. Installation 1. NOTE: Lubricate the EPC solenoid O-rings with clean automatic transmission fluid. Install the EPC solenoid, bracket and bolt. ^ Tighten to 10 Nm (89 inch lbs.). 2. Inspect the lead frame for damage. ^ Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted. ^ If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, ^ Install a new lead frame. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70E/4R75E > Page 6184 3. Connect the molded lead frame to the solenoids. 1 Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 2 Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 3 Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 4 Connect the bulkhead interconnector by pressing it in place by hand and fully seating the connector in place. 4. Install the transmission fluid pan and filter. Main Control Valve Body Main Control Valve Body Special Tools Removal 1. Drain transmission fluid and remove the transmission fluid pan and filter. For additional information, refer to Fluid Pan, Gasket and Filter. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70E/4R75E > Page 6185 Check Ball Location 2. CAUTION: Do not pull on the molded 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 manual control valve detent lever bolt and spring. 4. Remove the 24 valve body-to-case bolts and the EPC bracket bolt. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70E/4R75E > Page 6186 5. 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 correct location prior to installing the bolts. Position the main control valve body gasket and main control valve body using 2 bolts as a guide. 2. NOTE: The main control valve body bolts will be tightened in later steps. Loosely install the long main control valve body bolts. 3. NOTE: The main control valve body bolts will be tightened in later steps. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70E/4R75E > Page 6187 Loosely install the 12 short main control valve body bolts. 4. NOTE: Lubricate the EPC solenoid O-rings with clean automatic transmission fluid. Position the EPC solenoid bracket and loosely install the bolt. 5. Install the manual control valve detent lever spring and loosely install the bolt. 6. Tighten the bolts in the sequence shown. ^ Tighten to 10 Nm (89 inch lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70E/4R75E > Page 6188 7. Inspect the lead frame for damage. ^ Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted. ^ If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, install a new lead frame. 8. Connect the molded lead frame to the solenoids. ^ Connect the bulkhead inter-connector by pressing it in place by hand and fully seating the connector in place. ^ Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. ^ Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. ^ Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. ^ Make sure that the terminals pass fully through the connector slots. 9. Install the transmission filter and pan. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70E/4R75E > Page 6189 Valve Body: Service and Repair 6HP26 Main Control Valve Body Special Tools Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Do not pull on the wire harness to disconnect the connector or damage to the connector will occur. Disconnect the main transmission electrical harness by twisting the outer shell and pulling back on the connector. 3. Remove and discard the transmission fluid pan drain plug and allow the fluid to drain. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70E/4R75E > Page 6190 4. Install a new fluid pan drain plug. ^ Tighten to 8 Nm (71 inch lbs.). 5. NOTE: The transmission fluid pan, gasket, filter and magnets are serviced as a complete unit. Remove the transmission fluid pan assembly. 6. Press the release tab and pull down on the bulkhead connector retainer. 7. With the release tab down, pull the outer shell of the bulkhead electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70E/4R75E > Page 6191 8. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit. Pull the outer shell of the bulkhead electrical connector out of the transmission. 9. Remove the 10 bolts from the mechatronic assembly and remove the mechatronic assembly. Installation 1. Position the mechatronic assembly in place and loosely install the 10 retaining bolts. 2. Tighten the mechatronic bolts in the sequence shown. ^ Tighten to 8 Nm (71 inch lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70E/4R75E > Page 6192 3. Install new O-rings seals on the outer shell of the bulkhead electrical connector. 4. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit. With the release tab down, push the outer shell of the bulkhead electrical connector into the transmission. 5. Press up on the tab and lock the outer shell of the bulkhead electrical connector in place. 6. Install the fluid pan. ^ Tighten the bolts in a crisscross pattern. ^ Tighten to 8 Nm (71 inch lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70E/4R75E > Page 6193 7. Connect the main transmission electrical harness by pushing it in and twisting the outer shell to lock it in place. 8. CAUTION: The fluid fill plug located on the side of the transmission is near the exhaust system. The exhaust will be extremely hot during this procedure. Use care when working near the exhaust and the heat shields. Remove the fluid fill plug. ^ The fill plug is located on the RH rear side of the case near the transmission electrical connector. 9. CAUTION: The use of any other transmission fluid than specified can result in the transmission failing to operate correctly or transmission failure. CAUTION: The fluid fill plug located on the side of the transmission is near the exhaust system. The exhaust will be extremely hot during this procedure. Use care when working near the exhaust and the heat shields. Fill the transmission. ^ Add 4.7 liters (5 quarts) of clean automatic transmission fluid to the transmission through the fluid fill hole. Stop when the fluid runs out of the bottom of the hole. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70E/4R75E > Page 6194 10. CAUTION: The fluid fill plug located on the side of the transmission is near the exhaust system. The exhaust will be extremely hot during this procedure. Use care when working near the exhaust and the heat shields. Install the fluid fill plug. ^ Tighten to 35 Nm (26 ft. lbs.). 11. Start the engine. Move the transmission range selector lever through all the gear ranges, checking for engagements. 12. With the engine idling (600 - 750 rpm) in PARK and the transmission temperature at 30°C - 50°C (86°F - 122°F), check and adjust the transmission fluid level. 13. CAUTION: The fluid fill plug located on the side of the transmission is near the exhaust system. The exhaust will be extremely hot during this procedure. Use care when working near the exhaust and the heat shields. With the engine still running in PARK, check the fluid level. ^ If more fluid is needed, remove the fluid fill plug and fill with clean automatic transmission fluid until the fluid runs out of the bottom of the hole. 14. Install the fluid fill plug. ^ Tighten to 35 Nm (26 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity FRONT AXLE ...................................................................................................................................... ................................. 3.5 - 3.7 pints (1.8 - 2.0 liters) REAR AXLE Conventional differential ................................................................................................. ..................................................................... 4.5 pints (2.13 liters) Limited-slip differential ................. ..................................................................................................................................................... 4.25 pints (2.01 liters) NOTE: Your vehicles rear axle is filled with a synthetic rear axle lubricant and is considered lubricated for life. These lubricants are not to be checked or changed unless a leak is suspected, service is required or the axle has been submerged in water. The axle lubricant should be changed any time the axle has been submerged in water. NOTE: Add 4 oz. (118 ml) of Additive Friction Modifier XL-3 (or equivalent) for complete refill of Ford Limited Slip axles. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 6200 Fluid - Differential: Fluid Type Specifications Differential Fluid Type REAR AXLE Motorcraft SAE 75W-140 Synthetic Rear Axle Lube Ford P/N ...................................... .............................................................................................................................................................. . XY-75W140-QL Ford Specification ................................................................................................... ................................................................................... WSL-M2C192-A FRONT AXLE Motorcraft SAE 80W-90 Premium Rear Axle Lube Ford P/N ...................................... .............................................................................................................................................................. ... XY-80W90-QL Ford Specification ................................................................................................... ................................................................................... WSP-M2C197-A NOTE: Add 4.0 oz. (118 ml) of Additive Friction Modifier XL-3 or equivalent for complete refill of Ford Limited Slip rear axles. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair Differential Output Shaft Bearing: Service and Repair Stub Shaft Pilot Bearing and Seal Special Tools Material 1. Remove the halfshaft assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Page 6205 2. NOTE: If removing the stub shaft pilot bearing oil seal only, engage the tangs of the special tool on the stub shaft pilot bearing oil seal. Using the special tools, remove the stub shaft pilot bearing and the stub shaft pilot bearing oil seal. 1 Firmly engage the tangs of the special tool on the stub shaft pilot bearing. 2 Remove the bearing and the stub shaft pilot bearing oil seal. 3. Inspect the seal Journal for rust, nicks and scratches. Polish the seal journal surface with fine crocus cloth, if necessary. 4. Lubricate the new stub shaft pilot bearing with axle lubricant. 5. CAUTION: Installation of the stub shaft pilot bearing or stub shaft oil seat without the correct tools can result in early bearing or seal failure. If the stub shaft pilot bearing becomes cocked in the bore during installation, remove it and install a new one. Place the stub shaft pilot bearing onto the special tools. 6. Install the stub shaft pilot bearing into the rear axle housing bore. 7. NOTE: Do not disassemble the new oil seal. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Page 6206 Install the seal onto the special tools. 8. Carefully align the stub shaft pilot bearing seal with the housing bore and install the stub shaft pilot bearing seal flush in the differential housing. ^ Strike only the handle. Directly striking the installer tool will damage the seal. 9. Remove and discard the halfshaft excluder seal, if equipped. 10. CAUTION: Inspect the stub shaft seal journal for rust, nicks or scratches prior to installing the halfshaft. Polish the seat journal with fine crocus cloth, if required. Install the halfshaft. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 9.57-Inch - Rear Drive Axle/Differential Pinion Flange: Service and Repair Ford 9.57-Inch - Rear Drive Axle/Differential Drive Pinion Flange and Drive Pinion Seal Special Tools Materials Removal CAUTION: Remove the rear wheel and tire assemblies, brake calipers and brake discs to prevent brake drag during the drive pinion bearing preload adjustment. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 9.57-Inch - Rear Drive Axle/Differential > Page 6211 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. Failure to follow these instructions may result in personal injury and vehicle damage. With the vehicle in NEUTRAL, position the vehicle on a hoist. For additional information refer to Maintenance/Service and Repair. 2. Remove the rear wheel and tire assemblies. 3. CAUTION: Do not allow the brake caliper to hang from the brake hose. Provide a suitable support. Remove the rear brake calipers and the brake discs. Position the brake calipers aside. 4. Remove the rear driveshaft assembly. 5. Install a Nm (inch lbs.) torque wrench on the nut and record the torque necessary to maintain rotation of the drive pinion gear through several revolutions. 6. CAUTION: After removing the pinion nut, discard it. Use a new nut for installation. Use the special tool to hold the pinion flange while removing the pinion nut. 7. Index-mark the drive pinion flange and the drive pinion gear stem to maintain initial balance during installation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 9.57-Inch - Rear Drive Axle/Differential > Page 6212 8. Using the special tool, remove the drive pinion flange. 9. Force up on the metal flange of the drive pinion seal. Install gripping pliers and strike with a hammer until the pinion seal is removed. Installation 1. Lubricate the lips of the new drive pinion seal with grease. 2. CAUTION: If the drive pinion seal becomes misaligned during installation, remove it and install a new seal. Using the special tool, install the drive pinion seal. 3. Lubricate the drive pinion flange splines with rear axle lubricant. 4. NOTE: Disregard the index marks if installing a new drive pinion flange. Position the drive pinion flange. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 9.57-Inch - Rear Drive Axle/Differential > Page 6213 5. Using the special tool, install the drive pinion flange. 6. Position the new drive pinion nut. 7. CAUTION: Do not under any circumstance loosen the nut to reduce preload. If it is necessary to reduce preload, install a new drive pinion collapsible spacer and nut. CAUTION: Remove the special tool while taking preload readings with the Nm (inch-pound) torque wrench. Use the special tool to hold the pinion flange while tightening the nut. ^ Rotate the pinion occasionally to make sure the pinion bearings seat correctly. Take frequent pinion bearing torque preload readings by rotating the drive pinion gear with a Nm (inch lbs.) torque wrench. ^ If the preload recorded prior to disassembly is lower than the specification for used bearings, tighten the nut to specification. If the preload recorded prior to disassembly is higher than the specification for used bearings, tighten the nut to the original reading as recorded. ^ Refer to the torque specification for used pinion bearings. 8. CAUTION: Install the driveshaft with new bolts. If new bolts are not available, apply seater to the threads of the original bolts. CAUTION: Align the index marks. CAUTION: The driveshaft flange yoke fits tightly on the pinion flange pilot. To make sure that the yoke seats squarely on the flange, tighten the bolts evenly in a cross pattern as shown. Install the rear driveshaft. 9. Install the rear brake discs and the brake calipers. 10. Install the rear wheel and tire assemblies. 11. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 9.57-Inch - Rear Drive Axle/Differential > Page 6214 12. If equipped with air suspension, reactivate the system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Ford 9.57-Inch - Rear Drive Axle/Differential > Page 6215 Pinion Flange: Service and Repair Ford 8.8-Inch - Front Drive Axle/Differential Drive Pinion Seal Special Tools Removal 1. Remove the front axle universal joint flange. 2. CAUTION: Do not damage the front axle housing. Force up on the metal flange of the rear axle drive pinion seal. Install gripping pliers and strike with a hammer to remove the pinion seal. Installation 1. Clean the pinion seal bore and use the Drive Pinion Oil Seal Installer to install the pinion seal. 2. Install the front axle universal joint flange. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Ford 9.57-Inch - Rear Drive Axle/Differential Seals and Gaskets: Service and Repair Ford 9.57-Inch - Rear Drive Axle/Differential Stub Shaft Pilot Bearing and Seal Stub Shaft Pilot Bearing and Seal Special Tools Material Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Ford 9.57-Inch - Rear Drive Axle/Differential > Page 6220 1. Remove the halfshaft assembly. 2. NOTE: If removing the stub shaft pilot bearing oil seal only, engage the tangs of the special tool on the stub shaft pilot bearing oil seal. Using the special tools, remove the stub shaft pilot bearing and the stub shaft pilot bearing oil seal. 1 Firmly engage the tangs of the special tool on the stub shaft pilot bearing. 2 Remove the bearing and the stub shaft pilot bearing oil seal. 3. Inspect the seal Journal for rust, nicks and scratches. Polish the seal journal surface with fine crocus cloth, if necessary. 4. Lubricate the new stub shaft pilot bearing with axle lubricant. 5. CAUTION: Installation of the stub shaft pilot bearing or stub shaft oil seat without the correct tools can result in early bearing or seal failure. If the stub shaft pilot bearing becomes cocked in the bore during installation, remove it and install a new one. Place the stub shaft pilot bearing onto the special tools. 6. Install the stub shaft pilot bearing into the rear axle housing bore. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Ford 9.57-Inch - Rear Drive Axle/Differential > Page 6221 7. NOTE: Do not disassemble the new oil seal. Install the seal onto the special tools. 8. Carefully align the stub shaft pilot bearing seal with the housing bore and install the stub shaft pilot bearing seal flush in the differential housing. ^ Strike only the handle. Directly striking the installer tool will damage the seal. 9. Remove and discard the halfshaft excluder seal, if equipped. 10. CAUTION: Inspect the stub shaft seal journal for rust, nicks or scratches prior to installing the halfshaft. Polish the seat journal with fine crocus cloth, if required. Install the halfshaft. Drive Pinion Flange and Drive Pinion Seal Drive Pinion Flange and Drive Pinion Seal Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Ford 9.57-Inch - Rear Drive Axle/Differential > Page 6222 Special Tools Materials Removal CAUTION: Remove the rear wheel and tire assemblies, brake calipers and brake discs to prevent brake drag during the drive pinion bearing preload adjustment. 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. Failure to follow these instructions may result in personal injury and vehicle damage. With the vehicle in NEUTRAL, position the vehicle on a hoist. For additional information refer to Maintenance/Service and Repair. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Ford 9.57-Inch - Rear Drive Axle/Differential > Page 6223 2. Remove the rear wheel and tire assemblies. 3. CAUTION: Do not allow the brake caliper to hang from the brake hose. Provide a suitable support. Remove the rear brake calipers and the brake discs. Position the brake calipers aside. 4. Remove the rear driveshaft assembly. 5. Install a Nm (inch lbs.) torque wrench on the nut and record the torque necessary to maintain rotation of the drive pinion gear through several revolutions. 6. CAUTION: After removing the pinion nut, discard it. Use a new nut for installation. Use the special tool to hold the pinion flange while removing the pinion nut. 7. Index-mark the drive pinion flange and the drive pinion gear stem to maintain initial balance during installation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Ford 9.57-Inch - Rear Drive Axle/Differential > Page 6224 8. Using the special tool, remove the drive pinion flange. 9. Force up on the metal flange of the drive pinion seal. Install gripping pliers and strike with a hammer until the pinion seal is removed. Installation 1. Lubricate the lips of the new drive pinion seal with grease. 2. CAUTION: If the drive pinion seal becomes misaligned during installation, remove it and install a new seal. Using the special tool, install the drive pinion seal. 3. Lubricate the drive pinion flange splines with rear axle lubricant. 4. NOTE: Disregard the index marks if installing a new drive pinion flange. Position the drive pinion flange. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Ford 9.57-Inch - Rear Drive Axle/Differential > Page 6225 5. Using the special tool, install the drive pinion flange. 6. Position the new drive pinion nut. 7. CAUTION: Do not under any circumstance loosen the nut to reduce preload. If it is necessary to reduce preload, install a new drive pinion collapsible spacer and nut. CAUTION: Remove the special tool while taking preload readings with the Nm (inch-pound) torque wrench. Use the special tool to hold the pinion flange while tightening the nut. ^ Rotate the pinion occasionally to make sure the pinion bearings seat correctly. Take frequent pinion bearing torque preload readings by rotating the drive pinion gear with a Nm (inch lbs.) torque wrench. ^ If the preload recorded prior to disassembly is lower than the specification for used bearings, tighten the nut to specification. If the preload recorded prior to disassembly is higher than the specification for used bearings, tighten the nut to the original reading as recorded. ^ Refer to the torque specification for used pinion bearings. 8. CAUTION: Install the driveshaft with new bolts. If new bolts are not available, apply seater to the threads of the original bolts. CAUTION: Align the index marks. CAUTION: The driveshaft flange yoke fits tightly on the pinion flange pilot. To make sure that the yoke seats squarely on the flange, tighten the bolts evenly in a cross pattern as shown. Install the rear driveshaft. 9. Install the rear brake discs and the brake calipers. 10. Install the rear wheel and tire assemblies. 11. Lower the vehicle. 12. If equipped with air suspension, reactivate the system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Ford 9.57-Inch - Rear Drive Axle/Differential > Page 6226 Seals and Gaskets: Service and Repair Ford 8.8-Inch - Front Drive Axle/Differential Drive Pinion Seal Special Tools Removal 1. Remove the front axle universal joint flange. 2. CAUTION: Do not damage the front axle housing. Force up on the metal flange of the rear axle drive pinion seal. Install gripping pliers and strike with a hammer to remove the pinion seal. Installation 1. Clean the pinion seal bore and use the Drive Pinion Oil Seal Installer to install the pinion seal. 2. Install the front axle universal joint flange. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Specifications > Front Drive Halfshafts Axle Shaft Assembly: Specifications Front Drive Halfshafts General Specifications Torque Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Specifications > Front Drive Halfshafts > Page 6232 Axle Shaft Assembly: Specifications Rear Drive Halfshafts General Specifications Torque Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Description and Operation > Front Drive Halfshafts Axle Shaft Assembly: Description and Operation Front Drive Halfshafts Front Drive Halfshafts Front Wheel Halfshaft and Joint, Disassembled View Front Wheel Halfshaft and Joint, Disassembled View New halfshaft components are available as follows: ^ A repair kit includes the boots, clamps, snap ring, retaining ring and grease. ^ A new inboard CV joint (plunge-type). ^ A new outboard CV joint and interconnecting shaft assembly includes the outboard front wheel halfshaft joint (fixed-type), boot and clamps. ^ A new integrated wheel end disconnect assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Description and Operation > Front Drive Halfshafts > Page 6235 Axle Shaft Assembly: Description and Operation Rear Drive Halfshafts Rear Drive Halfshafts ^ The RH and LH halfshafts are different lengths, with the LH halfshaft being the longer of the 2. ^ Inboard and outboard CV joints connect to a splined shaft. ^ An axle circlip retains the splined inboard CV joint to the differential side gear. Install a new axle circlip every time the halfshaft is removed from the vehicle. ^ A rear axle wheel hub retainer secures the side shaft assembly (interconnecting shaft and outboard CV joint) to the rear hub. Install a new rear axle wheel hub retainer every time you remove the halfshaft from the vehicle. Halfshaft Handling CAUTION: Never pick up or hold the halfshaft by the inboard or outboard CV joint only. NOTE: Only the inner CV joints are removable for installation of new CV boots and clamps. The boots and clamps are the only serviced parts of the halfshaft assembly. Handle all halfshaft components carefully during removal and installation procedures. ^ The halfshaft assemblies are not repairable. Install new assemblies if worn/damaged. ^ To separate the halfshaft from the rear hub, press the outboard CV joint from the rear hub. ^ To separate the halfshaft from the differential, apply a load to the back face of the inboard CV joint assembly to overcome the axle circlip. ^ Do not over-angle the CV joints. ^ Install new differential stub shaft seals whenever the halfshafts are removed. ^ Damage will occur to an assembled inboard CV joint if it is over-plunged outward from the joint housing. ^ Never use a hammer to remove or install the halfshafts. ^ Never use the halfshaft assembly as a lever to position other components. Always support the free end of the halfshaft. ^ Do not allow the boots to contact sharp edges or hot exhaust components. ^ Handle the halfshaft by the interconnecting shaft only to avoid pull-apart and potential damage to the CV joints. ^ Do not drop assembled halfshafts. The impact can cut the boots from the inside without evidence of external damage. Wheel and Tire Balancing, Rear WARNING: Do not balance the rear wheels and tires while mounted on the vehicle. Hoisting CAUTION: Use a frame-contact hoist only. Vehicle or component damage can result if other types of hoists are used. Never raise the vehicle using the halfshafts as lift points. Undercoating and Rustproofing During undercoating and rustproofing procedures, protect the boots from the coating materials. Foreign materials on the rubber boots will cause extreme advanced wear. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation Axle Shaft Assembly: Service and Repair Removal and Installation Front Drive Halfshafts Halfshaft Removal and Installation 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 left rear quarter trim panel. 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. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the front wheel and tire assembly. 3. Remove the dust cap. 4. Remove and discard the axle nut. ^ To install, tighten to 27 Nm (20 ft. lbs.). 5. Remove the vacuum/vent line at the vacuum/vent port of the integrated wheel end disconnect. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation > Page 6238 6. Remove the 3 integrated wheel end (IWE) retaining bolts to the steering knuckle. ^ To install, tighten to 12 Nm (9 ft. lbs.). 7. Remove the tie-rod end nut. ^ Disconnect the tie-rod end from the steering knuckle. ^ Discard the tie-rod end nut. ^ To install, tighten to 150 Nm (111 ft. lbs.). 8. Remove the upper ball joint nut. ^ Disconnect the upper ball Joint from the steering knuckle. ^ Discard the upper ball joint nut. ^ To install, tighten to 150 Nm (111 ft. lbs.). 9. CAUTION: Do not damage the hub seal. NOTE: Allow the steering knuckle to swing outboard while keeping the constant velocity shaft pushed inboard. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation > Page 6239 Once clearance is available, remove the constant velocity shaft Joint outboard end and integrated wheel end disconnect from the steering knuckle hub bearing. 10. Remove the IWE disconnect from the outboard constant velocity joint housing. 11. Remove the 6 halfshaft-to-axle bolts. ^ To install, tighten to 82 Nm (60 ft. lbs.). 12. Separate the halfshaft from the axle and the hub, and remove the assembly from the vehicle. 13. CAUTION: Verify the spline engagement by checking for spline lash before installing the halfshaft nut. To install, reverse the removal procedure. ^ Install a new axle nut, tie-rod end nut and an upper ball joint nut. Rear Drive Halfshafts Halfshaft Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation > Page 6240 Special Tools Removal and Installation NOTE: This procedure applies to both rear halfshaft assemblies. 1. CAUTION: Do not loosen the rear axle wheel hub retainer until after the wheel and tire assembly is removed from the vehicle. Wheel bearing damage will occur if the wheel bearing is unloaded with the weight of the vehicle applied. With the vehicle in NEUTRAL, raise and support the vehicle. 2. Remove the rear wheel and tire assembly. 3. NOTE: Have an assistant press the brake pedal to keep the axle from rotating. Remove and discard the rear axle wheel hub retainer and the washer. ^ To install, tighten to 345 Nm (254 ft. lbs.). 4. Using a suitable hub puller, separate the halfshaft from the knuckle. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation > Page 6241 5. Disconnect the toe link from the rear knuckle. ^ To install, tighten to 55 Nm (41 ft. lbs.). 6. Remove the bolt retaining the knuckle to the lower control arm. ^ To install, tighten to 400 Nm (295 ft. lbs.). 7. Pivot the rear knuckle on the upper control arm bolts and support the knuckle in a raised position. 8. CAUTION: Do not damage the axle shaft oil seal or the machined sealing surface on the inboard CV joint housing. CAUTION: Do not allow the splines on inboard CV joint housing to touch the axle shaft oil seal. NOTE: A circlip retains the inboard CV joint housing to the differential side gear in the axle. Using the special tool, disengage the inboard CV joint housing from the differential side gear. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation > Page 6242 9. Remove the halfshaft assembly from the vehicle. 10. Remove and discard the halfshaft retainer circlip. 11. Remove and discard the halfshaft excluder seal, if equipped. ^ Do not install a new excluder seal. 12. CAUTION: Always install a new differential stub shaft seal. CAUTION: Always install the halfshaft with a new retainer circlip and a new rear axle wheel hub retainer. CAUTION: Never use power tools to tighten the rear axle wheel hub retainer. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation > Page 6243 Axle Shaft Assembly: Service and Repair Disassembly and Assembly Front Drive Halfshafts Halfshaft Special Tools Material Disassembly 1. Remove the halfshaft from the vehicle. 2. CAUTION: Do not damage the boot. Remove the boot clamps. 3. Separate the boot from the inboard CV joint housing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation > Page 6244 4. Remove the retaining ring. 5. Remove the inboard CV joint housing. 6. Index-mark the inner race and ball cage. 7. Remove the 6 balls. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation > Page 6245 8. Remove the snap ring. 9. Remove the inner race and the ball cage. 10. Remove the inboard boot. 11. Remove the boot clamps. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation > Page 6246 12. Remove the outboard boot. 13. NOTE: If the grease is contaminated, clean and inspect the joint for wear. Install a new outboard CV Joint and interconnecting shaft assembly if worn/damaged. Check the grease for contamination. Assembly 1. Position the outboard boot on the shaft. 2. Pack the outboard CV Joint with 165 grams (5.82 ounces) of grease. 1 Use constant velocity joint grease or equivalent provided in the boot kit. 2 Spread any remaining grease from the kit evenly inside the boot. 3. Install the outboard boot. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation > Page 6247 1 Clean the boot mounting surface. 2 Seat the boot in the Joint boot groove. 4. Make sure a shaft groove is exposed by positioning the small end of the boot in the groove closest to the constant velocity joint housing. 5. Position the boot clamps. 6. NOTE: Tighten the through-bolt until the tool is in the CLOSED position. Using the special tool, install the 2 boot clamps. 7. Position the boot clamp on the shaft. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation > Page 6248 8. Position the inboard boot on the shaft. 9. Position the ball cage on the shaft with the tapered end facing the boot. 10. NOTE: Align the index marks. Position the inner race on the shaft with the counterbored end facing the boot. 11. Install the snap ring. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation > Page 6249 12. Lubricate and position the 6 balls. ^ Use constant velocity joint grease or equivalent provided in the boot kit. 13. Fill the inboard CV joint housing with 235 grams (8.29 ounces) of grease. ^ Use constant velocity joint grease or equivalent provided in the boot kit. 14. Make sure a shaft groove is exposed by positioning the small end of the boot in the groove closest to the constant velocity joint housing. 15. Position the boot clamp on the inboard CV Joint housing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation > Page 6250 16. Position the inboard CV Joint housing on the ball and race assembly. 17. Install the retaining ring. 18. Remove any excess grease from the mating surface. Seat the boot in the joint boot groove. 19. Set the halfshaft assembled length to specification. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation > Page 6251 20. CAUTION: Do not damage the boot. Insert a dull screwdriver blade under the boot to release the pressure. 21. NOTE: Tighten the through-bolt until the tool is in the closed position. Using the special tool, install the 2 boot clamps. 22. NOTE: Maintain a clean work surface. Compress the integrated wheel end disconnect on the bench to collapse the vacuum chamber. 23. While the integrated wheel end disconnect is collapsed, install a vacuum cap on the vacuum port. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation > Page 6252 24. CAUTION: Do not install the integrated wheel end disconnect in the knuckle. It must be installed on the outer constant velocity joint housing. Install the integrated wheel end disconnect on the outer constant velocity Joint housing. 25. CAUTION: Verify the spline engagement by checking for spline lash before installing the halfshaft nut. Install the halfshaft in the vehicle. Rear Drive Halfshafts Halfshaft Joint Special Tools Materials Disassembly 1. Remove the halfshaft assembly from the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation > Page 6253 2. For the inboard CV joint, carry out the following: 1 Remove and discard the boot clamps. 1 Use diagonal cutters to cut the clamp. 2 Remove the inboard CV joint housing. 3. NOTE: Install the halfshaft in a soft-jaw vise. For the inboard CV joint, carry out the following: 1 Remove and discard the retainer circlip. 2 Slide the boot away from the CV joint. 4. Using a suitable 3-jaw puller, remove the CV joint. 5. Remove and discard the tri-lobe insert and the boot. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation > Page 6254 6. NOTE: The outboard CV joint is not removable from the halfshaft. The boot must be removed or installed from the inboard CV joint side of the shaft. For the outboard CV joint, carry out the following: 1 Remove and discard the boot clamps. 2 Remove and discard the boot. 7. Inspect the grease, packed in the inboard CV joint and the outboard CV Joint, for contamination. Rub some of the grease from each joint between 2 fingers. Any gritty feeling indicates contamination. Wash all of the grease from the inboard CV joint, the inboard CV joint housing, the outboard CV Joint and the interconnecting shaft. Thoroughly dry all of the components and inspect them for wear or damage. Discard the assembly, if necessary. Only proceed as follows if not discarding the assembly. 8. On the inboard end, remove and discard the retainer circlip. Assembly 1. NOTE: Clean any excess grease from the boot mounting surfaces before installing the boot. For the outboard CV joint, carry out the following: 1 Slide the boot on the interconnecting shaft. 2 Pack the outboard CV joint with 275 grams (9.7 ounces) of grease. 3 Spread any remaining grease evenly inside the boot. 4 Install the boot by seating it in the groove in the CV joint housing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation > Page 6255 2. NOTE: Tighten the through-bolt until the special tool is in the closed position. Using the special tool, install both boot clamps. 3. NOTE: Install the halfshaft in a soft-jaw vise. NOTE: The lip on the end of the tri-lobe insert must seat against the end of the boot. For the inboard CV joint, carry out the following: 1 Position the clamp on the interconnecting shaft. 2 Position the boot on the interconnecting shaft. 3 Install the tri-lobe insert. 4. NOTE: One side of the inboard CV joint has a chamfer cut in the edge of joint at the inner diameter near the splines. Install the inboard CV Joint so that the chamfer faces the outboard end of the halfshaft. Install the CV joint. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation > Page 6256 5. Install the retainer circlip. 6. NOTE: Clean any excess grease from the boot mounting surfaces before installing the boot. For the inboard CV joint, carry out the following: 1 Pack the inboard CV joint housing with 325 grams (11.5 ounces) of grease. 2 Spread any remaining grease evenly inside the boot and on the CV joint. 3 Install the inboard CV Joint housing, seating the boot in the groove in the housing. 7. Set the halfshaft assembled length to specification. 1 Measure the entire assembly length. 2 Push in or pull out on the inner joint as necessary to adjust the halfshaft assembled length to specification. 3 Hold the inner joint to prevent the assembled length from changing, and insert a small flat-blade screwdriver between the boot and the Joint to equalize the pressure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Installation > Page 6257 8. NOTE: Tighten the through-bolt until the special tool is in the closed position. Using the special tool, install both boot clamps. 9. CAUTION: Do not over expand or twist the circlip during installation. Install a new retainer circlip. 10. Install the halfshaft assembly in the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-19-3 > Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking Seals and Gaskets: Customer Interest Drivetrain - Rear Axle Seal(s) Leaking TSB 08-19-3 09/29/08 UNITIZED SEAL DIAGNOSIS - LEAK / GREASE OIL SEPARATION - AXLE BEARING SEAL 8.8 IFS, 8.8 IRS, AND 9.75 IRS AXLES FORD: 2002-2008 Explorer 2003-2008 Expedition 2006-2008 Explorer Sport Trac LINCOLN: 2003-2005 Aviator 2003-2008 Navigator MERCURY: 2002-2008 Mountaineer This article supersedes TSB 06-22-05 to update the model years, Part List and Service Procedure. ISSUE Some 2006-2008 Expedition, Navigator, Explorer, Explorer Sport Track, and Mountaineer vehicles equipped with rear axle unitized cartridge seal, 2007-2008 Expedition-Navigator AWD equipped with front and rear axle unitized cartridge seal. 2003-2005 Expedition-Navigator, 2002-2005, Explorer-Mountaineer, 2003-2005 Aviator equipped with unitized cartridge rear axle seal, may exhibit oil separation from the internal lube found in the unitized cartridge seal. This oil separation appears to be, and is often misdiagnosed, as an axle lube leak. The majority of the vehicles with this condition will be located in northern Canada and Alaska due to the extreme cold weather. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE DO NOT REPLACE THE UNITIZED CARTRIDGE SEAL UNTIL YOU COMPLETE THIS DIAGNOSTIC SERVICE PROCEDURE. FAILURE TO PROPERLY DIAGNOSE THE ISSUE MAY RESULT IN UNNECESSARILY REPLACING THE SEAL, RESULTING IN A REPEAT CONCERN. NOTE THIS DIAGNOSTIC PROCEDURE IS ONLY NECESSARY ON VEHICLES WITH THE NEW UNITIZED CARTRIDGE SEAL. THIS SEAL HAS BEEN USED IN PRODUCTION FROM 2006 MODEL YEAR TO PRESENT, HOWEVER, SOME VEHICLES BUILT PRIOR TO 2006 MODEL YEAR MAY HAVE THIS NEW UPDATED UNITIZED CARTRIDGE SEAL INSTALLED AS A SERVICE REPAIR. 1. Raise vehicle, refer to Workshop Manual (WSM), Section 100-02. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-19-3 > Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking > Page 6266 NOTE IF SEAL IS OLD DESIGN RADIAL LIP SEAL STYLE, (SEE FIGURES 1 AND 2 TO IDENTIFY RADIAL LIP SEAL) THERE IS NO INTERNAL GREASE PRESENT IN SEAL TO SEPARATE. THIS TSB DOES NOT APPLY. REFER TO WORKSHOP MANUAL DIAGNOSTIC. 2. Check axle half shaft seal to ensure that it is unitized cartridge design. 3. Clean axle housing around the seal area using Motorcraft® Metal Brake Parts Cleaner or equivalent cleaner. Wipe lube or oil with rag and let the housing dry. 4. Add 0.5 to 1 ounce (14.8 to 29.6 ml) Rotunda Dye-Lite® Leak Detection Dye for Gasoline Engine Oil 164-R3700, also contained in 164-R0756 to the axle following the appropriate Workshop Manual. NOTE ADDING THE DYE ON SOME VEHICLES WILL REQUIRE THE REAR WHEEL ABS SPEED SENSOR TO BE REMOVED. REFER TO THE APPROPRIATE WORKSHOP MANUAL DRAIN AND FILL PROCEDURE. 5. Road test vehicle a minimum distance 15 miles (24 km) at a minimum speed of 25 MPH (40 Km/h). NOTE A BRIGHT ORANGE AREA WILL IDENTIFY AXLE LUBE LEAK. FOR EXTREMELY SMALL OIL SEPARATION, ADDITIONAL AXLE OPERATION TIME MAY BE REQUIRED FOR THE LEAK TO APPEAR. 6. Raise vehicle to check for signs of leak. a. Use Rotunda 12V Master UV Leak Detector Kit 164-R0756 or equivalent to look for signs of leak. 7. If there is not a verifiable lube leak, clean axle near seal area and return the vehicle to the customer. NOTE IF THERE IS NO SIGNS OF LUBE LEAK, THIS MEANS THAT THE SUBSTANCE WHICH WAS PRESENT PRIOR TO THE PROCEDURE WAS OIL WHICH HAD SEPARATED FROM THE GREASE INTERNAL TO THE SEAL. THIS OIL IS A PRE-LUBE, AND IS NOT NECESSARY ONCE THE AXLE SEAL IS BROKEN IN. ONCE THE OIL SEPARATION HAS OCCURRED, THERE SHOULD BE NO Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-19-3 > Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking > Page 6267 FURTHER OIL SEPARATION FROM THE SEAL. REMOVING THE SEAL AND INSTALLING A NEW SEAL MIGHT CREATE A SITUATION WHERE THE OIL WILL SEPARATE, RESULTING IN THE SAME CONCERN. 8. If there is a verifiable axle lube leak, replace seal following the Workshop Manual (WSM), Section 205, or look at instruction sheet included in Axle Shaft Seal Kit. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081903A 2003-2008 Expedition, 0.9 Hr. Navigator: INSPECT Axle Seal Leaks. Includes Time to Add Oil Dye and Road Test. This Labor Operation Can Be Claimed With Any Of The Labor Operations In This Article. (Do Not Use With 4139A, 4139A2) 081903A 2002-2008 Explorer, 0.7 Hr. Mountaineer, 2007-2008 Explorer Sport Trac, 2002-2005 Aviator: INSPECT Axle Seal Leaks. Includes Time to Add Oil Dye and Road Test. This Labor Operation Can Be Claimed With Any Of The Labor Operations In This Article. (Do Not Use With 4139A, 4139A2) 081903B 2003-2008 Expedition 1.3 Hrs. Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A, 4139A2) 081903C 2003-2008 Expedition 2.2 Hrs. Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A, 4139A2) 081903D 2003-2008 Expedition, 0.7 Hr. Navigator: Replace Rear Axle Stub Shaft Seal. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-19-3 > Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking > Page 6268 Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A, B, Or C (Do Not Use With 4139A, 4139A2) 081903D 2006-2008 Explorer, 1.1 Hrs. Mountaineer, 2007-2008 Explorer Sport Trac :Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) 081903D 2002-2005 Explorer, 0.9 Hr. Mountaineer:Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) 081903D 2003-2005 Aviator:Replace 0.8 Hr. Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) 081903E 2003-2008 Expedition, 1.2 Hrs. Navigator: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A, B, Or C (Do Not Use With 4139A, 4139A2) 081903E 2006-2008 Explorer, 2.1 Hrs. Mountaineer, 2007-2008 Explorer Sport Trac Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) 081903E 2002-2005 Explorer, 1.5 Hrs. Mountaineer: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A (Do Not Use With Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-19-3 > Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking > Page 6269 4139A, 4139A2) 081903E 2003-2005 Aviator: 1.6 Hrs. Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) DEALER CODING CONDITION BASIC PART NO. CODE 4A109 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-19-3 > Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking Seals and Gaskets: All Technical Service Bulletins Drivetrain - Rear Axle Seal(s) Leaking TSB 08-19-3 09/29/08 UNITIZED SEAL DIAGNOSIS - LEAK / GREASE OIL SEPARATION - AXLE BEARING SEAL 8.8 IFS, 8.8 IRS, AND 9.75 IRS AXLES FORD: 2002-2008 Explorer 2003-2008 Expedition 2006-2008 Explorer Sport Trac LINCOLN: 2003-2005 Aviator 2003-2008 Navigator MERCURY: 2002-2008 Mountaineer This article supersedes TSB 06-22-05 to update the model years, Part List and Service Procedure. ISSUE Some 2006-2008 Expedition, Navigator, Explorer, Explorer Sport Track, and Mountaineer vehicles equipped with rear axle unitized cartridge seal, 2007-2008 Expedition-Navigator AWD equipped with front and rear axle unitized cartridge seal. 2003-2005 Expedition-Navigator, 2002-2005, Explorer-Mountaineer, 2003-2005 Aviator equipped with unitized cartridge rear axle seal, may exhibit oil separation from the internal lube found in the unitized cartridge seal. This oil separation appears to be, and is often misdiagnosed, as an axle lube leak. The majority of the vehicles with this condition will be located in northern Canada and Alaska due to the extreme cold weather. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE DO NOT REPLACE THE UNITIZED CARTRIDGE SEAL UNTIL YOU COMPLETE THIS DIAGNOSTIC SERVICE PROCEDURE. FAILURE TO PROPERLY DIAGNOSE THE ISSUE MAY RESULT IN UNNECESSARILY REPLACING THE SEAL, RESULTING IN A REPEAT CONCERN. NOTE THIS DIAGNOSTIC PROCEDURE IS ONLY NECESSARY ON VEHICLES WITH THE NEW UNITIZED CARTRIDGE SEAL. THIS SEAL HAS BEEN USED IN PRODUCTION FROM 2006 MODEL YEAR TO PRESENT, HOWEVER, SOME VEHICLES BUILT PRIOR TO 2006 MODEL YEAR MAY HAVE THIS NEW UPDATED UNITIZED CARTRIDGE SEAL INSTALLED AS A SERVICE REPAIR. 1. Raise vehicle, refer to Workshop Manual (WSM), Section 100-02. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-19-3 > Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking > Page 6275 NOTE IF SEAL IS OLD DESIGN RADIAL LIP SEAL STYLE, (SEE FIGURES 1 AND 2 TO IDENTIFY RADIAL LIP SEAL) THERE IS NO INTERNAL GREASE PRESENT IN SEAL TO SEPARATE. THIS TSB DOES NOT APPLY. REFER TO WORKSHOP MANUAL DIAGNOSTIC. 2. Check axle half shaft seal to ensure that it is unitized cartridge design. 3. Clean axle housing around the seal area using Motorcraft® Metal Brake Parts Cleaner or equivalent cleaner. Wipe lube or oil with rag and let the housing dry. 4. Add 0.5 to 1 ounce (14.8 to 29.6 ml) Rotunda Dye-Lite® Leak Detection Dye for Gasoline Engine Oil 164-R3700, also contained in 164-R0756 to the axle following the appropriate Workshop Manual. NOTE ADDING THE DYE ON SOME VEHICLES WILL REQUIRE THE REAR WHEEL ABS SPEED SENSOR TO BE REMOVED. REFER TO THE APPROPRIATE WORKSHOP MANUAL DRAIN AND FILL PROCEDURE. 5. Road test vehicle a minimum distance 15 miles (24 km) at a minimum speed of 25 MPH (40 Km/h). NOTE A BRIGHT ORANGE AREA WILL IDENTIFY AXLE LUBE LEAK. FOR EXTREMELY SMALL OIL SEPARATION, ADDITIONAL AXLE OPERATION TIME MAY BE REQUIRED FOR THE LEAK TO APPEAR. 6. Raise vehicle to check for signs of leak. a. Use Rotunda 12V Master UV Leak Detector Kit 164-R0756 or equivalent to look for signs of leak. 7. If there is not a verifiable lube leak, clean axle near seal area and return the vehicle to the customer. NOTE IF THERE IS NO SIGNS OF LUBE LEAK, THIS MEANS THAT THE SUBSTANCE WHICH WAS PRESENT PRIOR TO THE PROCEDURE WAS OIL WHICH HAD SEPARATED FROM THE GREASE INTERNAL TO THE SEAL. THIS OIL IS A PRE-LUBE, AND IS NOT NECESSARY ONCE THE AXLE SEAL IS BROKEN IN. ONCE THE OIL SEPARATION HAS OCCURRED, THERE SHOULD BE NO Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-19-3 > Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking > Page 6276 FURTHER OIL SEPARATION FROM THE SEAL. REMOVING THE SEAL AND INSTALLING A NEW SEAL MIGHT CREATE A SITUATION WHERE THE OIL WILL SEPARATE, RESULTING IN THE SAME CONCERN. 8. If there is a verifiable axle lube leak, replace seal following the Workshop Manual (WSM), Section 205, or look at instruction sheet included in Axle Shaft Seal Kit. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081903A 2003-2008 Expedition, 0.9 Hr. Navigator: INSPECT Axle Seal Leaks. Includes Time to Add Oil Dye and Road Test. This Labor Operation Can Be Claimed With Any Of The Labor Operations In This Article. (Do Not Use With 4139A, 4139A2) 081903A 2002-2008 Explorer, 0.7 Hr. Mountaineer, 2007-2008 Explorer Sport Trac, 2002-2005 Aviator: INSPECT Axle Seal Leaks. Includes Time to Add Oil Dye and Road Test. This Labor Operation Can Be Claimed With Any Of The Labor Operations In This Article. (Do Not Use With 4139A, 4139A2) 081903B 2003-2008 Expedition 1.3 Hrs. Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A, 4139A2) 081903C 2003-2008 Expedition 2.2 Hrs. Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A, 4139A2) 081903D 2003-2008 Expedition, 0.7 Hr. Navigator: Replace Rear Axle Stub Shaft Seal. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-19-3 > Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking > Page 6277 Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A, B, Or C (Do Not Use With 4139A, 4139A2) 081903D 2006-2008 Explorer, 1.1 Hrs. Mountaineer, 2007-2008 Explorer Sport Trac :Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) 081903D 2002-2005 Explorer, 0.9 Hr. Mountaineer:Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) 081903D 2003-2005 Aviator:Replace 0.8 Hr. Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) 081903E 2003-2008 Expedition, 1.2 Hrs. Navigator: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A, B, Or C (Do Not Use With 4139A, 4139A2) 081903E 2006-2008 Explorer, 2.1 Hrs. Mountaineer, 2007-2008 Explorer Sport Trac Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) 081903E 2002-2005 Explorer, 1.5 Hrs. Mountaineer: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A (Do Not Use With Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-19-3 > Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking > Page 6278 4139A, 4139A2) 081903E 2003-2005 Aviator: 1.6 Hrs. Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) DEALER CODING CONDITION BASIC PART NO. CODE 4A109 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 6279 Seals and Gaskets: By Symptom Technical Service Bulletin # 08-19-3 Date: 080929 Drivetrain - Rear Axle Seal(s) Leaking TSB 08-19-3 09/29/08 UNITIZED SEAL DIAGNOSIS - LEAK / GREASE OIL SEPARATION - AXLE BEARING SEAL 8.8 IFS, 8.8 IRS, AND 9.75 IRS AXLES FORD: 2002-2008 Explorer 2003-2008 Expedition 2006-2008 Explorer Sport Trac LINCOLN: 2003-2005 Aviator 2003-2008 Navigator MERCURY: 2002-2008 Mountaineer This article supersedes TSB 06-22-05 to update the model years, Part List and Service Procedure. ISSUE Some 2006-2008 Expedition, Navigator, Explorer, Explorer Sport Track, and Mountaineer vehicles equipped with rear axle unitized cartridge seal, 2007-2008 Expedition-Navigator AWD equipped with front and rear axle unitized cartridge seal. 2003-2005 Expedition-Navigator, 2002-2005, Explorer-Mountaineer, 2003-2005 Aviator equipped with unitized cartridge rear axle seal, may exhibit oil separation from the internal lube found in the unitized cartridge seal. This oil separation appears to be, and is often misdiagnosed, as an axle lube leak. The majority of the vehicles with this condition will be located in northern Canada and Alaska due to the extreme cold weather. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE DO NOT REPLACE THE UNITIZED CARTRIDGE SEAL UNTIL YOU COMPLETE THIS DIAGNOSTIC SERVICE PROCEDURE. FAILURE TO PROPERLY DIAGNOSE THE ISSUE MAY RESULT IN UNNECESSARILY REPLACING THE SEAL, RESULTING IN A REPEAT CONCERN. NOTE THIS DIAGNOSTIC PROCEDURE IS ONLY NECESSARY ON VEHICLES WITH THE NEW UNITIZED CARTRIDGE SEAL. THIS SEAL HAS BEEN USED IN PRODUCTION FROM 2006 MODEL YEAR TO PRESENT, HOWEVER, SOME VEHICLES BUILT PRIOR TO 2006 MODEL YEAR MAY HAVE THIS NEW UPDATED UNITIZED CARTRIDGE SEAL INSTALLED AS A SERVICE REPAIR. 1. Raise vehicle, refer to Workshop Manual (WSM), Section 100-02. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 6280 NOTE IF SEAL IS OLD DESIGN RADIAL LIP SEAL STYLE, (SEE FIGURES 1 AND 2 TO IDENTIFY RADIAL LIP SEAL) THERE IS NO INTERNAL GREASE PRESENT IN SEAL TO SEPARATE. THIS TSB DOES NOT APPLY. REFER TO WORKSHOP MANUAL DIAGNOSTIC. 2. Check axle half shaft seal to ensure that it is unitized cartridge design. 3. Clean axle housing around the seal area using Motorcraft® Metal Brake Parts Cleaner or equivalent cleaner. Wipe lube or oil with rag and let the housing dry. 4. Add 0.5 to 1 ounce (14.8 to 29.6 ml) Rotunda Dye-Lite® Leak Detection Dye for Gasoline Engine Oil 164-R3700, also contained in 164-R0756 to the axle following the appropriate Workshop Manual. NOTE ADDING THE DYE ON SOME VEHICLES WILL REQUIRE THE REAR WHEEL ABS SPEED SENSOR TO BE REMOVED. REFER TO THE APPROPRIATE WORKSHOP MANUAL DRAIN AND FILL PROCEDURE. 5. Road test vehicle a minimum distance 15 miles (24 km) at a minimum speed of 25 MPH (40 Km/h). NOTE A BRIGHT ORANGE AREA WILL IDENTIFY AXLE LUBE LEAK. FOR EXTREMELY SMALL OIL SEPARATION, ADDITIONAL AXLE OPERATION TIME MAY BE REQUIRED FOR THE LEAK TO APPEAR. 6. Raise vehicle to check for signs of leak. a. Use Rotunda 12V Master UV Leak Detector Kit 164-R0756 or equivalent to look for signs of leak. 7. If there is not a verifiable lube leak, clean axle near seal area and return the vehicle to the customer. NOTE IF THERE IS NO SIGNS OF LUBE LEAK, THIS MEANS THAT THE SUBSTANCE WHICH WAS PRESENT PRIOR TO THE PROCEDURE WAS OIL WHICH HAD SEPARATED FROM THE GREASE INTERNAL TO THE SEAL. THIS OIL IS A PRE-LUBE, AND IS NOT NECESSARY ONCE THE AXLE SEAL IS BROKEN IN. ONCE THE OIL SEPARATION HAS OCCURRED, THERE SHOULD BE NO Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 6281 FURTHER OIL SEPARATION FROM THE SEAL. REMOVING THE SEAL AND INSTALLING A NEW SEAL MIGHT CREATE A SITUATION WHERE THE OIL WILL SEPARATE, RESULTING IN THE SAME CONCERN. 8. If there is a verifiable axle lube leak, replace seal following the Workshop Manual (WSM), Section 205, or look at instruction sheet included in Axle Shaft Seal Kit. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081903A 2003-2008 Expedition, 0.9 Hr. Navigator: INSPECT Axle Seal Leaks. Includes Time to Add Oil Dye and Road Test. This Labor Operation Can Be Claimed With Any Of The Labor Operations In This Article. (Do Not Use With 4139A, 4139A2) 081903A 2002-2008 Explorer, 0.7 Hr. Mountaineer, 2007-2008 Explorer Sport Trac, 2002-2005 Aviator: INSPECT Axle Seal Leaks. Includes Time to Add Oil Dye and Road Test. This Labor Operation Can Be Claimed With Any Of The Labor Operations In This Article. (Do Not Use With 4139A, 4139A2) 081903B 2003-2008 Expedition 1.3 Hrs. Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A, 4139A2) 081903C 2003-2008 Expedition 2.2 Hrs. Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A, 4139A2) 081903D 2003-2008 Expedition, 0.7 Hr. Navigator: Replace Rear Axle Stub Shaft Seal. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 6282 Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A, B, Or C (Do Not Use With 4139A, 4139A2) 081903D 2006-2008 Explorer, 1.1 Hrs. Mountaineer, 2007-2008 Explorer Sport Trac :Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) 081903D 2002-2005 Explorer, 0.9 Hr. Mountaineer:Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) 081903D 2003-2005 Aviator:Replace 0.8 Hr. Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) 081903E 2003-2008 Expedition, 1.2 Hrs. Navigator: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A, B, Or C (Do Not Use With 4139A, 4139A2) 081903E 2006-2008 Explorer, 2.1 Hrs. Mountaineer, 2007-2008 Explorer Sport Trac Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) 081903E 2002-2005 Explorer, 1.5 Hrs. Mountaineer: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A (Do Not Use With Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 6283 4139A, 4139A2) 081903E 2003-2005 Aviator: 1.6 Hrs. Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) DEALER CODING CONDITION BASIC PART NO. CODE 4A109 42 Disclaimer Technical Service Bulletin # 08-19-3 Date: 080929 Drivetrain - Rear Axle Seal(s) Leaking TSB 08-19-3 09/29/08 UNITIZED SEAL DIAGNOSIS - LEAK / GREASE OIL SEPARATION - AXLE BEARING SEAL 8.8 IFS, 8.8 IRS, AND 9.75 IRS AXLES FORD: 2002-2008 Explorer 2003-2008 Expedition 2006-2008 Explorer Sport Trac LINCOLN: 2003-2005 Aviator 2003-2008 Navigator MERCURY: 2002-2008 Mountaineer This article supersedes TSB 06-22-05 to update the model years, Part List and Service Procedure. ISSUE Some 2006-2008 Expedition, Navigator, Explorer, Explorer Sport Track, and Mountaineer vehicles equipped with rear axle unitized cartridge seal, 2007-2008 Expedition-Navigator AWD equipped with front and rear axle unitized cartridge seal. 2003-2005 Expedition-Navigator, 2002-2005, Explorer-Mountaineer, 2003-2005 Aviator equipped with unitized cartridge rear axle seal, may exhibit oil separation from the internal lube found in the unitized cartridge seal. This oil separation appears to be, and is often misdiagnosed, as an axle lube leak. The majority of the vehicles with this condition will be located in northern Canada and Alaska due to the extreme cold weather. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE DO NOT REPLACE THE UNITIZED CARTRIDGE SEAL UNTIL YOU COMPLETE THIS DIAGNOSTIC SERVICE PROCEDURE. FAILURE TO PROPERLY DIAGNOSE THE ISSUE MAY RESULT IN UNNECESSARILY REPLACING THE SEAL, RESULTING IN A REPEAT CONCERN. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 6284 NOTE THIS DIAGNOSTIC PROCEDURE IS ONLY NECESSARY ON VEHICLES WITH THE NEW UNITIZED CARTRIDGE SEAL. THIS SEAL HAS BEEN USED IN PRODUCTION FROM 2006 MODEL YEAR TO PRESENT, HOWEVER, SOME VEHICLES BUILT PRIOR TO 2006 MODEL YEAR MAY HAVE THIS NEW UPDATED UNITIZED CARTRIDGE SEAL INSTALLED AS A SERVICE REPAIR. 1. Raise vehicle, refer to Workshop Manual (WSM), Section 100-02. NOTE IF SEAL IS OLD DESIGN RADIAL LIP SEAL STYLE, (SEE FIGURES 1 AND 2 TO IDENTIFY RADIAL LIP SEAL) THERE IS NO INTERNAL GREASE PRESENT IN SEAL TO SEPARATE. THIS TSB DOES NOT APPLY. REFER TO WORKSHOP MANUAL DIAGNOSTIC. 2. Check axle half shaft seal to ensure that it is unitized cartridge design. 3. Clean axle housing around the seal area using Motorcraft® Metal Brake Parts Cleaner or equivalent cleaner. Wipe lube or oil with rag and let the housing dry. 4. Add 0.5 to 1 ounce (14.8 to 29.6 ml) Rotunda Dye-Lite® Leak Detection Dye for Gasoline Engine Oil 164-R3700, also contained in 164-R0756 to the axle following the appropriate Workshop Manual. NOTE ADDING THE DYE ON SOME VEHICLES WILL REQUIRE THE REAR WHEEL ABS SPEED SENSOR TO BE REMOVED. REFER TO THE APPROPRIATE WORKSHOP MANUAL DRAIN AND FILL PROCEDURE. 5. Road test vehicle a minimum distance 15 miles (24 km) at a minimum speed of 25 MPH (40 Km/h). NOTE A BRIGHT ORANGE AREA WILL IDENTIFY AXLE LUBE LEAK. FOR EXTREMELY SMALL OIL SEPARATION, ADDITIONAL AXLE OPERATION TIME MAY BE REQUIRED FOR THE LEAK TO APPEAR. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 6285 6. Raise vehicle to check for signs of leak. a. Use Rotunda 12V Master UV Leak Detector Kit 164-R0756 or equivalent to look for signs of leak. 7. If there is not a verifiable lube leak, clean axle near seal area and return the vehicle to the customer. NOTE IF THERE IS NO SIGNS OF LUBE LEAK, THIS MEANS THAT THE SUBSTANCE WHICH WAS PRESENT PRIOR TO THE PROCEDURE WAS OIL WHICH HAD SEPARATED FROM THE GREASE INTERNAL TO THE SEAL. THIS OIL IS A PRE-LUBE, AND IS NOT NECESSARY ONCE THE AXLE SEAL IS BROKEN IN. ONCE THE OIL SEPARATION HAS OCCURRED, THERE SHOULD BE NO FURTHER OIL SEPARATION FROM THE SEAL. REMOVING THE SEAL AND INSTALLING A NEW SEAL MIGHT CREATE A SITUATION WHERE THE OIL WILL SEPARATE, RESULTING IN THE SAME CONCERN. 8. If there is a verifiable axle lube leak, replace seal following the Workshop Manual (WSM), Section 205, or look at instruction sheet included in Axle Shaft Seal Kit. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081903A 2003-2008 Expedition, 0.9 Hr. Navigator: INSPECT Axle Seal Leaks. Includes Time to Add Oil Dye and Road Test. This Labor Operation Can Be Claimed With Any Of The Labor Operations In This Article. (Do Not Use With 4139A, 4139A2) 081903A 2002-2008 Explorer, 0.7 Hr. Mountaineer, 2007-2008 Explorer Sport Trac, 2002-2005 Aviator: INSPECT Axle Seal Leaks. Includes Time to Add Oil Dye and Road Test. This Labor Operation Can Be Claimed With Any Of The Labor Operations In This Article. (Do Not Use With 4139A, 4139A2) 081903B 2003-2008 Expedition 1.3 Hrs. Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A, 4139A2) 081903C 2003-2008 Expedition 2.2 Hrs. Navigator: Replace Front Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 6286 Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A, 4139A2) 081903D 2003-2008 Expedition, 0.7 Hr. Navigator: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A, B, Or C (Do Not Use With 4139A, 4139A2) 081903D 2006-2008 Explorer, 1.1 Hrs. Mountaineer, 2007-2008 Explorer Sport Trac :Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) 081903D 2002-2005 Explorer, 0.9 Hr. Mountaineer:Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) 081903D 2003-2005 Aviator:Replace 0.8 Hr. Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) 081903E 2003-2008 Expedition, 1.2 Hrs. Navigator: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A, B, Or C (Do Not Use With 4139A, 4139A2) 081903E 2006-2008 Explorer, 2.1 Hrs. Mountaineer, 2007-2008 Explorer Sport Trac Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 6287 Claimed With A (Do Not Use With 4139A, 4139A2) 081903E 2002-2005 Explorer, 1.5 Hrs. Mountaineer: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) 081903E 2003-2005 Aviator: 1.6 Hrs. Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) DEALER CODING CONDITION BASIC PART NO. CODE 4A109 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications FRONT WHEEL BEARINGS High Temperature 4x4 Front Axle & Wheel Bearing Grease Ford P/N .............................................................................................................................................. ...................................................... E8TZ-19590-A Ford Specification ................................................ ................................................................................................................................... ESA-M1C198-A Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 6291 Wheel Bearing: Service and Repair Wheel Bearing and Wheel Hub Removal and Installation 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 LH rear quarter trim panel. 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. Failure to follow these instructions may result in personal injury. CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. If equipped, turn the air suspension switch to the OFF position. 2. With the vehicle in NEUTRAL, position it on a hoist. 3. NOTE: Have an assistant press the brake pedal to keep the axle from rotating. Remove and discard the rear halfshaft nut and washer. ^ To install, tighten to 300 Nm (221 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 6292 4. Using a suitable hub puller, separate the outboard CV Joint from the wheel hub. 5. CAUTION: Do not allow the caliper to hang from the brake hose or damage to the hose can result. Remove the bolts and position the caliper aside. ^ Support the caliper using mechanic's wire. ^ To install, tighten to 190 Nm (140 ft. lbs.). 6. Remove the brake disc. 7. Disconnect the wheel speed sensor electrical connector and detach the wheel speed sensor harness from the retainer. 8. Remove the bolt and detach the harness from the retainers. To install, tighten the bolt to 15 Nm (11 ft. lbs.). 9. Remove the 4 wheel bearing and hub assembly bolts, the wheel bearing assembly and the wheel speed sensor as an assembly. ^ Route the sensor wiring through the access hole in the brake shield. ^ Discard the bolts. ^ To install, tighten to 185 Nm (136 ft. lbs.). 10. If necessary, remove the wheel speed sensor bolt and the wheel speed sensor from the wheel bearing and hub assembly. ^ To install, tighten to 15 Nm (13 ft. lbs.). 11. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front axle nut ....................................................................................................................................... ...................................................... 27 Nm (20 ft.lbs.) Rear axle wheel hub retainer ........................... ...................................................................................................................................... 345 Nm (254 ft.lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations > Page 6300 C1157 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Diagrams > Rear Rear - Navigator 4WD, Expedition 4WD And 2WD Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Diagrams > Rear > Page 6306 Front, Expedition And Navigator Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Front Drive/Propeller Shaft: Service and Repair Driveshaft - Front Driveshaft - Front Material Removal and Installation 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 rear jack storage 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. Failure to follow these instructions may result in personal injury. With the vehicle in NEUTRAL, position the vehicle on a hoist. For additional information, refer to Maint./Service. 2. Remove the 3 front driveshaft shield nuts and the front driveshaft shield. ^ To install, tighten to 25 Nm (18 ft. lbs.). 3. Index-mark the front flange to the pinion flange. Index-mark the rear flange to the transfer case flange. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 6309 4. Remove the 4 rear flange-to-transfer case flange bolts. ^ To install, tighten to 104 Nm (77 ft. lbs.). 5. Remove the 4 front flange-to-pinion flange bolts. ^ To install, tighten to 112 Nm (83 ft. lbs.). 6. Remove the front driveshaft from the vehicle. 7. CAUTION: If new bolts to retain the driveshaft to the axle and the driveshaft to the transfer case are not available, coat the threads of the original bolts with threadlock and sealer. CAUTION: The front driveshaft must be installed with the boot toward the transfer case to prevent damage to the boot from the exhaust system. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 6310 Drive/Propeller Shaft: Service and Repair Driveshaft - Rear Driveshaft - Rear, Expedition Material Removal and Installation 1. CAUTION: 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 rear jack storage area. Failure to do so can result in the unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Failure to follow these instructions may result in personal injury. With the vehicle in NEUTRAL, position the vehicle on a hoist. For additional information, refer to Maint./Service. 2. Index-mark the driveshaft flange to the rear axle pinion flange. 3. Remove the 4 driveshaft flange bolts. ^ To install, tighten to 112 Nm (83 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 6311 4. CAUTION: The driveshaft flange fits tightly on the rear axle pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft from the pinion flange. Pry only in the area shown, with a suitable tool, to disconnect the driveshaft flange from the pinion flange. Using a suitable tool, disconnect the driveshaft flange from the rear axle pinion flange. 5. NOTE: Do not rotate the driveshaft when removing the slip yoke from the transmission output shaft. Index-mark the driveshaft slip yoke and the transmission extension housing. Mark the transmission output shaft to the transmission extension housing after removing the driveshaft. 6. CAUTION: Coat the threads of the original bolts with sealer. CAUTION: The driveshaft flange fits tightly on the rear axle pinion flange pilot. To make sure that the driveshaft flange seats squarely on the pinion flange, tighten the bolts evenly in a cross pattern as shown. CAUTION: Make sure all index marks are aligned. To install, reverse the removal procedure. ^ Tighten the driveshaft flange bolts to 112 Nm (83 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 6312 Drive/Propeller Shaft: Service and Repair Driveshaft Slip Yoke Boot Driveshaft Slip Yoke Boot Material Removal and Installation 1. Remove the driveshaft. 2. Index the driveshaft to the center bearing for correct alignment during installation. 3. Disconnect the slip yoke boot. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 6313 4. Separate the driveshaft. 5. Remove the slip yoke boot. 6. NOTE: Lubricate the slip yoke splines with premium long-life grease. To install, reverse the removal procedure. ^ Align the index marks for correct alignment. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Ford 9.57-Inch - Rear Drive Axle/Differential Universal Joint: Service and Repair Ford 9.57-Inch - Rear Drive Axle/Differential Driveshaft Universal Joint - Single Cardan Special Tools Disassembly 1. Remove the driveshaft. 2. CAUTION: Do not clamp the driveshaft in the jaws of a vise or a similar holding fixture. Carefully place the driveshaft on a suitable workbench. 3. NOTE: Index the driveshaft components relative to the driveshaft tube. Make sure all components are reassembled in the same relationship to maintain correct balance. Index the driveshaft and driveshaft components. 4. Position the special tool in a vise. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Ford 9.57-Inch - Rear Drive Axle/Differential > Page 6318 5. Remove the snap rings from the universal joint. 6. NOTE: If necessary, use a pair of pliers to remove a bearing cup if it cannot be pressed out all the way. Remove the driveshaft flange yoke. 1 Position the driveshaft flange in the special tool. 2 Press out the bearing cup. 3 Rotate the driveshaft flange yoke. 4 Press on the spider to remove the remaining bearing cup. 5 Remove the driveshaft flange yoke. 7. Repeat the previous step to remove the remaining bearing cups and spider from the driveshaft. 8. Clean the yoke area at the end of the driveshaft and flange yoke. Assembly NOTE: Universal Joint service kits are to be installed as complete assemblies only. Do not use components from other universal joints. 1. Clamp the special tool in a vise. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Ford 9.57-Inch - Rear Drive Axle/Differential > Page 6319 2. Install a new bearing cup. 1 Start a new bearing cup into the driveshaft yoke. 2 Position a new spider in the driveshaft yoke. 3 Install the driveshaft into the special tool. 4 Press the bearing cup below the yoke surface. 3. Remove the driveshaft from the special tool and install the snap ring. 4. Repeat the previous steps to install the remaining bearing cups. 5. NOTE: Do not strike the bearings. If binding, strike the yoke with a brass or plastic hammer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Ford 9.57-Inch - Rear Drive Axle/Differential > Page 6320 Universal Joint: Service and Repair Ford 8.8-Inch - Front Drive Axle/Differential Universal Joint Flange - Front Special Tools Material 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 LH rear quarter trim 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. Position the vehicle on a hoist. 2. Remove the front wheel and tire assemblies. 3. CAUTION: Remove the front brake caliper to prevent drag during the drive pinion bearing preload adjustment. CAUTION: Do not allow the calipers to hang from the brake hoses. Remove the front brake calipers. Wire the caliper aside. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Ford 9.57-Inch - Rear Drive Axle/Differential > Page 6321 4. Index-mark the front driveshaft to the axle universal joint flange. 5. CAUTION: Do not allow the driveshaft to hang unsupported. Disconnect and support the front driveshaft. 1 Remove the 4 bolts. 2 Carefully disconnect and support the front driveshaft. 6. Using a Nm (inch/pound) torque wrench, measure the torque necessary to maintain pinion rotation. Record the measurement for reference during installation. 7. CAUTION: After removing the pinion nut, discard it. Use a new pinion nut for installation. Install the special tool and remove the pinion nut. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Ford 9.57-Inch - Rear Drive Axle/Differential > Page 6322 8. Index-mark the axle universal joint flange to the pinion stem. 9. Using the special tool, separate the axle universal joint flange from the pinion gear. 10. Remove the flange. 11. Inspect the axle universal Joint flange for burrs, the nut counterbore and the seal contact surface for nicks, and the bearing cone contact area for damage. Install a new flange if necessary. 12. Check the pinion stem splines for burrs. If burrs are evident, remove them with a fine crocus cloth. Installation 1. Lubricate the axle universal joint flange splines and the pinion seal. ^ Use front axle lubricant. 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Ford 9.57-Inch - Rear Drive Axle/Differential > Page 6323 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. ^ 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Ford 9.57-Inch - Rear Drive Axle/Differential > Page 6324 6. Inspect and, if necessary, fill the differential. ^ Use rear axle lubricant. 7. Lower the vehicle. 8. If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Flexplate bolts ..................................................................................................................................... ................................................. 80 Nm (59 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 6328 Flex Plate: Diagrams Engine - Lower End Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 6329 Engine - Lower End Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 6330 Engine - Lower End Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 6331 Flex Plate: Service and Repair Flexplate Removal and Installation 1. Remove the transmission. 2. Remove the 8 bolts and the flexplate. ^ To install, tighten to 80 Nm (59 ft. lbs.) in the sequence shown. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation TRANSMISSION CONTROL INDICATOR LAMP (TCIL) The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Description and Operation Power Take-Off: Description and Operation POWER TAKE-OFF (PTO) SWITCH AND CIRCUITS The PTO circuit is used by the PCM to disable some of the on-board diagnostics (OBD) monitors during PTO operation. The PTO switch is normally open. When the PTO unit is activated, the PTO switch is closed and battery voltage is supplied to the PTO input circuit. This indicates to the PCM that an additional load is being applied to the engine. The PTO indicator lamp illuminates when the PTO system is functioning correctly and flashes when the PTO system is damaged. When the PTO unit is activated, the PCM disables some OBD monitors, which may not function reliably during PTO operation. Without the PTO circuit information to the PCM, false diagnostic trouble codes (DTCs) may be set during PTO operation. Prior to an Inspection/Maintenance test, the vehicle will have to be operated with the PTO disengaged long enough to successfully complete the OBD Monitors. PTO CIRCUITS DESCRIPTION The 3 PTO input circuits are PTO mode, PTO engage, and PTO RPM. The PTO engage circuit is used when the operator is requesting the PCM to check the needed inputs required to initiate the PTO engagement. The PTO RPM circuit is used for the operator to request additional engine RPM for PTO operation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair Control Module: Service and Repair Four-Wheel Drive (4WD) Control Module Removal and Installation NOTE: The Four Wheel Drive (4WD) control module is integral to the Powertrain Control Module (PCM) and is not serviced separately. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 Four Wheel Drive Selector Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 6348 View 151-1 (Engine Compartment) The transfercase Low to High and High to Low relays are located in the Auxiliary relay box 1 located in the engine compartment. LH side, front. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Transfer Case Low to High Relay C1129 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Transfer Case Low to High Relay > Page 6351 C1173 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Testing and Inspection > Transfer Case Low to High Relay Four Wheel Drive Selector Relay: Testing and Inspection Transfer Case Low to High Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Testing and Inspection > Transfer Case Low to High Relay > Page 6354 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Testing and Inspection > Transfer Case Low to High Relay > Page 6355 Four Wheel Drive Selector Relay: Testing and Inspection Transfer Case High to Low Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Testing and Inspection > Transfer Case Low to High Relay > Page 6356 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions Brake Switch - TCC: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6363 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6364 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6365 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6366 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6367 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6368 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6369 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6370 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6371 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6372 Brake Switch - TCC: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6373 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6374 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6375 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6376 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6377 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6378 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6379 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Page 6380 Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - BPP switch is hardwired to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - BPP switch is hardwired to the Anti-Lock Brake System (ABS) Module, Lighting Control Module (LCM), or Rear Electronic Module (REM), the BPP signal is then broadcast over the network to be received by the PCM. - BPP switch is hardwired to the anti-lock brake system (ABS) traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations View 151-14 (Steering Column) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Overdrive Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6386 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6387 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6388 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6389 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6390 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6391 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6392 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6393 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6394 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6395 Overdrive Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6396 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6397 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6398 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6399 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6400 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6401 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6402 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6403 C2135 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor/Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6408 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6409 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6410 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6411 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6412 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6413 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6414 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6415 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6416 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6417 Throttle Position Sensor/Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6418 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6419 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6420 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6421 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6422 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6423 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6424 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Mode Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6429 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6430 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6431 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6432 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6433 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6434 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6435 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6436 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6437 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6438 Transmission Mode Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6439 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6440 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6441 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6442 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6443 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6444 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6445 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 6446 Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH (TCS) Typical Transmission Control Switch (TCS) Typical Transmission Control Switch (TCS) The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature, the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage overdrive. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 6450 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6453 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6454 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6455 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6456 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6457 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6458 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6459 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6460 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6461 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6462 Transmission Position Switch/Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6463 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6464 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6465 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6466 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6467 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6468 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6469 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6470 C167 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 6471 Transmission Position Switch/Sensor: Adjustments 4R70E/4R75E Transmission Range (TR) Sensor Adjustment Special Tools 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual lever shift control cable. 3. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control lever nut. 2 Remove the manual control lever. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 6472 4. Loosen the digital transmission range (TR) sensor bolts. 5. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 6. CAUTION: Tightening one bolt before tightening the other may cause the sensor to bind or become damaged. Using the special tool, align the digital TR sensor and tighten the bolts in an alternating sequence. ^ Tighten to 9 Nm (80 inch lbs.). 7. Install the manual control lever. ^ Position the manual control lever. 2 Install a new manual lever shaft outer nut. ^ Tighten to 33 Nm (24 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 6473 8. With the manual lever in overdrive connect the shift lever control cable. 9. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 6474 Transmission Position Switch/Sensor: Service and Repair 4R70E/4R75E Automatic Transmission Digital Transmission Range (TR) Sensor Special Tools Removal NOTE: Manual shift lever must be in the NEUTRAL position. 1. With the vehicle in NEUTRAL, position it on a hoist. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 6475 2. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual control lever shift control cable. 3. Disconnect the digital TR electrical connector. 4. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control nut. 2 Remove the manual control lever. 5. Remove the digital TR sensor bolts and the digital TR sensor. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 6476 1. Install the digital TR sensor and loosely install the bolts. 2. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 3. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. Tighten the digital TR sensor bolts. ^ Tighten to 9 Nm (80 inch lbs.). 4. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual control lever nut. ^ Tighten to 33 Nm (24 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 6477 5. Connect the digital TR sensor electrical connector. 6. Connect the shift cable end to the manual lever with the lever in the (D) position. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Turbine Shaft Speed (TSS) Sensor > Page 6482 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Turbine Shaft Speed (TSS) Sensor > Page 6483 Transmission Speed Sensor: Locations Output Shaft Speed (OSS) Sensor View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Turbine Shaft Speed (TSS) Sensor > Page 6484 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Speed Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6487 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6488 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6489 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6490 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6491 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6492 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6493 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6494 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6495 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6496 Transmission Speed Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6497 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6498 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6499 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6500 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6501 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6502 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6503 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6504 Transmission Speed Sensor: Connector Views C193 C143 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 6505 Transmission Speed Sensor: Service and Repair 4R70E/4R75E Automatic Transmission Speed Sensors Speed Sensors NOTE: Only remove the affected sensor. Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist, OSS sensor 2. Disconnect the output shaft speed (OSS) sensor electrical connector. 3. Remove the OSS sensor bolt. 4. Remove the OSS sensor. TSS sensor 5. Disconnect the turbine shaft speed (TSS) sensor electrical connector. 6. Remove the TSS sensor bolt. 7. Remove the TSS sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 6506 Installation TSS sensor 1. Lubricate the O-ring seal and install the TSS sensor. 2. Install the TSS sensor bolt. ^ Tighten to 11 Nm (8 ft. lbs.). 3. Connect the TSS sensor electrical connector. OSS sensor 4. Lubricate the O-ring seal and install the OSS sensor. 5. Install the OSS sensor bolt. ^ Tighten to 12 Nm (9 ft. lbs.). 6. Connect the OSS sensor electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations View 151-12 (Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 6511 C284 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair Control Module: Service and Repair Four-Wheel Drive (4WD) Control Module Removal and Installation NOTE: The Four Wheel Drive (4WD) control module is integral to the Powertrain Control Module (PCM) and is not serviced separately. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Case Capacity ....................................................................................................................... .................................................................... 2.0 Quarts Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 6520 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Fluid Type ..................................................................................................................................................... ............................................................. Mercon ATF Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Page 6521 Fluid - Transfer Case: Service and Repair Transfer Case Draining and Filling Special Tools Materials 1. Remove the drain plug and drain the fluid. Clean the drain plug and the drain plug area. Apply thread sealant to the drain plug threads. Reinstall the drain plug. ^ To install, tighten to 15 Nm (11 ft. lbs.). 2. Clean the area around the fill plug. Remove the fill plug. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Page 6522 3. CAUTION: Incorrect fluid fill can result in transfer case failure. Using the special tool, fill the transfer case to specification. ^ The fluid must be just below the fill plug hole. Fill the case until the fluid slowly flows over the fill plug threads. Clean the fluid from the fill plug area. 4. Apply thread sealant to the fill plug threads, then install the fill plug. ^ Tighten to 15 Nm (11 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations Four Wheel Drive Selector Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Page 6526 View 151-1 (Engine Compartment) The transfercase Low to High and High to Low relays are located in the Auxiliary relay box 1 located in the engine compartment. LH side, front. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Transfer Case Low to High Relay C1129 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Transfer Case Low to High Relay > Page 6529 C1173 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Testing and Inspection > Transfer Case Low to High Relay Four Wheel Drive Selector Relay: Testing and Inspection Transfer Case Low to High Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Testing and Inspection > Transfer Case Low to High Relay > Page 6532 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Testing and Inspection > Transfer Case Low to High Relay > Page 6533 Four Wheel Drive Selector Relay: Testing and Inspection Transfer Case High to Low Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Testing and Inspection > Transfer Case Low to High Relay > Page 6534 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations View 151-12 (Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 6538 C284 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair Control Module: Service and Repair Four-Wheel Drive (4WD) Control Module Removal and Installation NOTE: The Four Wheel Drive (4WD) control module is integral to the Powertrain Control Module (PCM) and is not serviced separately. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations Four Wheel Drive Selector Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Page 6546 View 151-1 (Engine Compartment) The transfercase Low to High and High to Low relays are located in the Auxiliary relay box 1 located in the engine compartment. LH side, front. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Transfer Case Low to High Relay C1129 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Transfer Case Low to High Relay > Page 6549 C1173 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Testing and Inspection > Transfer Case Low to High Relay Four Wheel Drive Selector Relay: Testing and Inspection Transfer Case Low to High Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Testing and Inspection > Transfer Case Low to High Relay > Page 6552 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Testing and Inspection > Transfer Case Low to High Relay > Page 6553 Four Wheel Drive Selector Relay: Testing and Inspection Transfer Case High to Low Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Testing and Inspection > Transfer Case Low to High Relay > Page 6554 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair Seals and Gaskets: Service and Repair Transfer Case Rear Output Shaft Oil Seal Special Tools 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. Failure to do this will result is unexpected inflation or deflation of the vehicle during these operations. With the vehicle in NEUTRAL, position it on a hoist. 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations View 151-12 (Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 6562 C284 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Pressure Regulating Solenoid: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6570 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6571 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6572 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6573 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6574 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6575 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6576 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6577 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6578 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6579 Pressure Regulating Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6580 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6581 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6582 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6583 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6584 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6585 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6586 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 6587 Solenoid Operation Chart Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 6588 Pressure Regulating Solenoid: Testing and Inspection 4R70E/4R75E Automatic Transmission Pinpoint Tests - OSC Equipped Vehicles Special Tools Any time an electrical connector or solenoid body is disconnected, inspect the connector for pin condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install a new connector or component as required. Shift Solenoids Pre-Diagnosis Use the following shift solenoid operation information when carrying out Pinpoint Test A. See: Testing and Inspection/Pinpoint Tests/Pinpoint Tests/Test A: Shift and Torque Converter Clutch Solenoids Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 6589 Solenoid Operation Chart Shift Solenoid Failure Mode Chart "Always off" (Part 1) Shift Solenoid Failure Mode Chart "Always off" (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 6590 Shift Solenoid Failure Mode Chart "Always off" (Part 3) Failed off due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck off. Shift Solenoid Failure Mode Chart "Always On" (Part 1) Shift Solenoid Failure Mode Chart "Always On" (Part 2) Shift Solenoid Failure Mode Chart "Always On" (Part 3) Failed on due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck on. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 6591 Pressure Regulating Solenoid: Service and Repair 4R70E/4R75E Electronic Pressure Control (EPC) Solenoid Special Tools Removal CAUTION: Do not pull on the molded 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. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid and remove the transmission fluid pan and filter. 3. 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 interconnector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 6592 4. Remove the EPC solenoid. Installation 1. NOTE: Lubricate the EPC solenoid O-rings with clean automatic transmission fluid. Install the EPC solenoid, bracket and bolt. ^ Tighten to 10 Nm (89 inch lbs.). 2. Inspect the lead frame for damage. ^ Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted. ^ If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, ^ Install a new lead frame. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 6593 3. Connect the molded lead frame to the solenoids. 1 Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 2 Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 3 Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 4 Connect the bulkhead interconnector by pressing it in place by hand and fully seating the connector in place. 4. Install the transmission fluid pan and filter. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator Column Shift Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Column Shift Brake Shift Interlock Actuator Column Shift Brake Shift Interlock Actuator - Column Shift Removal and Installation 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 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 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator Column Shift > Page 6598 latches. Please refer to the appropriate vehicle shop manual to determine 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). Disconnect the battery ground cable. Wait at least one minute before proceeding with the procedure to allow the backup power supply to deplete its energy. 2. Remove the supplemental restraint system (SRS) steering column clockspring. 3. Remove the 3 bolts and remove the clockspring mounting bracket from the steering column. ^ To install, tighten to 6 Nm (53 inch lbs.). 4. Remove the 3 screws and position the wiring harnesses aside. 5. Disconnect the interlock actuator electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator Column Shift > Page 6599 6. Remove the 2 screws and position the actuator aside. 7. Remove the 2 bolts and position the selector lever detent bracket aside. ^ To install, tighten to 6 Nm (53 inch lbs.). 8. Remove the shift lock actuator from the detent bracket and remove the shift lock actuator. 9. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Brake Shift Interlock Actuator Column Shift > Page 6600 Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Floor Shift Brake Shift Interlock Actuator Floor Shift Removal and Installation NOTE: The brake shift interlock actuator is not serviced individually. If replacement is required, install a new floor shift selector lever assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6605 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6606 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6607 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6608 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6609 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6610 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6611 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6612 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6613 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6614 Shift Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6615 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6616 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6617 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6618 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6619 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6620 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6621 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 6622 Solenoid Operation Chart Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 6623 Shift Solenoid: Testing and Inspection 4R70E/4R75E Automatic Transmission Pinpoint Tests - OSC Equipped Vehicles Special Tools Any time an electrical connector or solenoid body is disconnected, inspect the connector for pin condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install a new connector or component as required. Shift Solenoids Pre-Diagnosis Use the following shift solenoid operation information when carrying out Pinpoint Test A. See: Testing and Inspection/Pinpoint Tests/Pinpoint Tests/Test A: Shift and Torque Converter Clutch Solenoids Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 6624 Solenoid Operation Chart Shift Solenoid Failure Mode Chart "Always off" (Part 1) Shift Solenoid Failure Mode Chart "Always off" (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 6625 Shift Solenoid Failure Mode Chart "Always off" (Part 3) Failed off due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck off. Shift Solenoid Failure Mode Chart "Always On" (Part 1) Shift Solenoid Failure Mode Chart "Always On" (Part 2) Shift Solenoid Failure Mode Chart "Always On" (Part 3) Failed on due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck on. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 6626 Shift Solenoid: Service and Repair 4R70E/4R75E Electronic Pressure Control (EPC) Solenoid Special Tools Removal CAUTION: Do not pull on the molded 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. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid and remove the transmission fluid pan and filter. 3. 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 interconnector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 6627 4. Remove the EPC solenoid. Installation 1. NOTE: Lubricate the EPC solenoid O-rings with clean automatic transmission fluid. Install the EPC solenoid, bracket and bolt. ^ Tighten to 10 Nm (89 inch lbs.). 2. Inspect the lead frame for damage. ^ Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted. ^ If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, ^ Install a new lead frame. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 6628 3. Connect the molded lead frame to the solenoids. 1 Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 2 Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 3 Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 4 Connect the bulkhead interconnector by pressing it in place by hand and fully seating the connector in place. 4. Install the transmission fluid pan and filter. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6633 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6634 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6635 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6636 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6637 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6638 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6639 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6640 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6641 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6642 Torque Converter Clutch Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6643 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6644 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6645 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6646 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6647 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6648 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6649 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6650 Solenoid Operation Chart Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6651 Torque Converter Clutch Solenoid: Testing and Inspection 4R70E/4R75E Automatic Transmission Pinpoint Tests - OSC Equipped Vehicles Special Tools Any time an electrical connector or solenoid body is disconnected, inspect the connector for pin condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install a new connector or component as required. Shift Solenoids Pre-Diagnosis Use the following shift solenoid operation information when carrying out Pinpoint Test A. See: Testing and Inspection/Pinpoint Tests/Pinpoint Tests/Test A: Shift and Torque Converter Clutch Solenoids Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6652 Solenoid Operation Chart Shift Solenoid Failure Mode Chart "Always off" (Part 1) Shift Solenoid Failure Mode Chart "Always off" (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6653 Shift Solenoid Failure Mode Chart "Always off" (Part 3) Failed off due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck off. Shift Solenoid Failure Mode Chart "Always On" (Part 1) Shift Solenoid Failure Mode Chart "Always On" (Part 2) Shift Solenoid Failure Mode Chart "Always On" (Part 3) Failed on due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or hydraulically stuck on. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6654 Torque Converter Clutch Solenoid: Service and Repair 4R70E/4R75E Electronic Pressure Control (EPC) Solenoid Special Tools Removal CAUTION: Do not pull on the molded 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. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain transmission fluid and remove the transmission fluid pan and filter. 3. 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 interconnector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6655 4. Remove the EPC solenoid. Installation 1. NOTE: Lubricate the EPC solenoid O-rings with clean automatic transmission fluid. Install the EPC solenoid, bracket and bolt. ^ Tighten to 10 Nm (89 inch lbs.). 2. Inspect the lead frame for damage. ^ Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted. ^ If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, ^ Install a new lead frame. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6656 3. Connect the molded lead frame to the solenoids. 1 Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 2 Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 3 Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots. 4 Connect the bulkhead interconnector by pressing it in place by hand and fully seating the connector in place. 4. Install the transmission fluid pan and filter. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation TRANSMISSION CONTROL INDICATOR LAMP (TCIL) The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 > Service and Repair Control Module: Service and Repair Four-Wheel Drive (4WD) Control Module Removal and Installation NOTE: The Four Wheel Drive (4WD) control module is integral to the Powertrain Control Module (PCM) and is not serviced separately. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 Four Wheel Drive Selector Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 6670 View 151-1 (Engine Compartment) The transfercase Low to High and High to Low relays are located in the Auxiliary relay box 1 located in the engine compartment. LH side, front. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 > Diagrams > Transfer Case Low to High Relay C1129 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 > Diagrams > Transfer Case Low to High Relay > Page 6673 C1173 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 > Testing and Inspection > Transfer Case Low to High Relay Four Wheel Drive Selector Relay: Testing and Inspection Transfer Case Low to High Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 > Testing and Inspection > Transfer Case Low to High Relay > Page 6676 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 > Testing and Inspection > Transfer Case Low to High Relay > Page 6677 Four Wheel Drive Selector Relay: Testing and Inspection Transfer Case High to Low Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 > Testing and Inspection > Transfer Case Low to High Relay > Page 6678 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions Brake Switch - TCC: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6685 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6686 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6687 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6688 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6689 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6690 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6691 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6692 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6693 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6694 Brake Switch - TCC: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6695 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6696 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6697 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6698 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6699 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6700 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 6701 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Page 6702 Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - BPP switch is hardwired to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - BPP switch is hardwired to the Anti-Lock Brake System (ABS) Module, Lighting Control Module (LCM), or Rear Electronic Module (REM), the BPP signal is then broadcast over the network to be received by the PCM. - BPP switch is hardwired to the anti-lock brake system (ABS) traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations View 151-14 (Steering Column) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Overdrive Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6708 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6709 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6710 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6711 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6712 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6713 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6714 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6715 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6716 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6717 Overdrive Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6718 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6719 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6720 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6721 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6722 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6723 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6724 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6725 C2135 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor/Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6730 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6731 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6732 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6733 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6734 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6735 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6736 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6737 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6738 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6739 Throttle Position Sensor/Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6740 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6741 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6742 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6743 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6744 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6745 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6746 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Mode Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6751 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6752 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6753 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6754 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6755 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6756 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6757 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6758 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6759 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6760 Transmission Mode Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6761 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6762 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6763 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6764 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6765 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6766 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6767 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 6768 Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH (TCS) Typical Transmission Control Switch (TCS) Typical Transmission Control Switch (TCS) The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature, the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage overdrive. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 6772 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6775 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6776 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6777 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6778 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6779 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6780 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6781 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6782 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6783 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6784 Transmission Position Switch/Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6785 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6786 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6787 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6788 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6789 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6790 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6791 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6792 C167 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 6793 Transmission Position Switch/Sensor: Adjustments 4R70E/4R75E Transmission Range (TR) Sensor Adjustment Special Tools 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual lever shift control cable. 3. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control lever nut. 2 Remove the manual control lever. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 6794 4. Loosen the digital transmission range (TR) sensor bolts. 5. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 6. CAUTION: Tightening one bolt before tightening the other may cause the sensor to bind or become damaged. Using the special tool, align the digital TR sensor and tighten the bolts in an alternating sequence. ^ Tighten to 9 Nm (80 inch lbs.). 7. Install the manual control lever. ^ Position the manual control lever. 2 Install a new manual lever shaft outer nut. ^ Tighten to 33 Nm (24 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 6795 8. With the manual lever in overdrive connect the shift lever control cable. 9. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 6796 Transmission Position Switch/Sensor: Service and Repair 4R70E/4R75E Automatic Transmission Digital Transmission Range (TR) Sensor Special Tools Removal NOTE: Manual shift lever must be in the NEUTRAL position. 1. With the vehicle in NEUTRAL, position it on a hoist. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 6797 2. CAUTION: Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual control lever shift control cable. 3. Disconnect the digital TR electrical connector. 4. CAUTION: Discard the outer manual control lever shaft nut. Do not reuse. The old nut will not retain the torque specification. Remove the manual control lever. 1 Remove and discard the manual control nut. 2 Remove the manual control lever. 5. Remove the digital TR sensor bolts and the digital TR sensor. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 6798 1. Install the digital TR sensor and loosely install the bolts. 2. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug. 3. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. Tighten the digital TR sensor bolts. ^ Tighten to 9 Nm (80 inch lbs.). 4. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual control lever nut. ^ Tighten to 33 Nm (24 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 6799 5. Connect the digital TR sensor electrical connector. 6. Connect the shift cable end to the manual lever with the lever in the (D) position. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Turbine Shaft Speed (TSS) Sensor > Page 6804 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Turbine Shaft Speed (TSS) Sensor > Page 6805 Transmission Speed Sensor: Locations Output Shaft Speed (OSS) Sensor View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Turbine Shaft Speed (TSS) Sensor > Page 6806 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Speed Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6809 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6810 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6811 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6812 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6813 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6814 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6815 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6816 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6817 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6818 Transmission Speed Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6819 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6820 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6821 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6822 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6823 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6824 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6825 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6826 Transmission Speed Sensor: Connector Views C193 C143 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 6827 Transmission Speed Sensor: Service and Repair 4R70E/4R75E Automatic Transmission Speed Sensors Speed Sensors NOTE: Only remove the affected sensor. Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist, OSS sensor 2. Disconnect the output shaft speed (OSS) sensor electrical connector. 3. Remove the OSS sensor bolt. 4. Remove the OSS sensor. TSS sensor 5. Disconnect the turbine shaft speed (TSS) sensor electrical connector. 6. Remove the TSS sensor bolt. 7. Remove the TSS sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 6828 Installation TSS sensor 1. Lubricate the O-ring seal and install the TSS sensor. 2. Install the TSS sensor bolt. ^ Tighten to 11 Nm (8 ft. lbs.). 3. Connect the TSS sensor electrical connector. OSS sensor 4. Lubricate the O-ring seal and install the OSS sensor. 5. Install the OSS sensor bolt. ^ Tighten to 12 Nm (9 ft. lbs.). 6. Connect the OSS sensor electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations View 151-12 (Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 6833 C284 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Sensor Block > Component Information > Service and Repair ABS Sensor Block: Service and Repair Stability Control Sensor Cluster Removal and Installation NOTE: The lateral and longitudinal accelerometer and the roll rate sensor are located within the yaw rate sensor, stability control sensor cluster. 1. Remove the front floor console. For additional information, refer to Console. 2. Disconnect the stability control sensor cluster electrical connector. 3. Remove the 2 bolts and the stability control sensor cluster. ^ To install, tighten to 12 Nm (9 ft. lbs.). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Locations > Primary Brake Pressure Sensor View 151-1 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Locations > Primary Brake Pressure Sensor > Page 6843 View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Diagrams > Primary Brake Pressure Sensor C147 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Diagrams > Primary Brake Pressure Sensor > Page 6846 C148 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 6850 C135 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 6851 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System (ABS) Module Removal and Installation NOTE: When installing a new module, it must be calibrated and configured (either by download/upload or uploading the as-built data method). 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the anti-lock brake system (ABS) module electrical connector. 3. Remove the 3 bolts and the ABS module. ^ To install, tighten to 2 Nm (18 inch lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 6852 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control Unit (HCU) Material Removal and Installation WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable. For additional information, refer to Battery. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 6856 2. Disconnect the anti-lock brake system (ABS) module electrical connector. 3. CAUTION: Only authorized inlet hydraulic brake tubes should be used. These tubes are of specific design and only authorized parts should be used when installing new inlet brake tubes. NOTE: Plug each open port to prevent brake fluid from spilling. Disconnect the 6 brake tube fittings. ^ To install, tighten to 18 Nm (13 ft. lbs.). 4. Remove the 3 hydraulic control unit (HCU)-to-bracket bolts and the HCU. ^ To install, tighten to 9 Nm (80 inch lbs.). 5. To install, reverse the removal procedure. ^ Bleed the brake system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Service and Repair Lateral Accelerometer: Service and Repair Stability Control Sensor Cluster Removal and Installation NOTE: The lateral and longitudinal accelerometer and the roll rate sensor are located within the yaw rate sensor, stability control sensor cluster. 1. Remove the front floor console. For additional information, refer to Console. 2. Disconnect the stability control sensor cluster electrical connector. 3. Remove the 2 bolts and the stability control sensor cluster. ^ To install, tighten to 12 Nm (9 ft. lbs.). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Service and Repair Steering Angle Sensor: Service and Repair Steering Wheel Rotation Sensor Removal and Installation 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the steering wheel rotation sensor electrical connector. 3. Remove the 2 bolts and the steering wheel rotation sensor. ^ To install, tighten to 4 Nm (35 inch lbs.). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations View 151-24 (Center Console) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Page 6866 C280 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Right Front View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Right Front > Page 6871 View 151-1 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Right Front > Page 6872 View 151-36 (Chassis, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 6875 C440 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 6876 C160 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 6877 C426 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Front Wheel Speed Sensor - Front Removal and Installation 1. NOTE: If equipped, turn the air suspension switch to the OFF position. With the vehicle in NEUTRAL, position it on a hoist 2. Disconnect the wheel speed sensor electrical connector. 3. Remove the wheel speed sensor harness retainer bolt and detach the retainers. ^ To install, tighten to 12 Nm (9 ft. lbs.). 4. CAUTION: Do not allow the caliper to hang from the brake hose or damage to the hose can result. Remove the 2 caliper anchor bolts and position the caliper, pads and anchor plate aside. ^ Support the caliper with mechanic's wire. ^ To install, tighten to 200 Nm (148 ft. lbs.). 5. Remove the brake disc. 6. Remove the front wheel speed sensor bolt and the sensor. ^ To install, tighten to 18 Nm (13 ft. lbs.). 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 6880 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Rear Wheel Speed Sensor - Rear Removal and Installation 1. Remove the parking brake shoes. 2. Disconnect the wheel speed sensor harness from the retaining clips. 3. Remove the rear wheel speed sensor bolt and the sensor. ^ To install, tighten to 18 Nm (13 ft. lbs.). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Locations View 151-12 (Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Locations > Page 6884 C245 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Locations > Page 6885 Yaw Rate Sensor: Service and Repair Stability Control Sensor Cluster Removal and Installation NOTE: The lateral and longitudinal accelerometer and the roll rate sensor are located within the yaw rate sensor, stability control sensor cluster. 1. Remove the front floor console. For additional information, refer to Console. 2. Disconnect the stability control sensor cluster electrical connector. 3. Remove the 2 bolts and the stability control sensor cluster. ^ To install, tighten to 12 Nm (9 ft. lbs.). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > Customer Interest for Brake Bleeding: > 05-26-21 > Dec > 05 > Brakes - Unintended Brake Assist Brake Bleeding: Customer Interest Brakes - Unintended Brake Assist TSB 05-26-21 12/31/05 UNINTENDED BRAKE ASSIST FORD: 2003-2006 Expedition LINCOLN: 2003-2006 Navigator ISSUE Some 2003-2006 Expedition/Navigator may exhibit excessive pedal travel and/or low pedal effort, due to the mechanical or electronic brake assist being activated. ACTION Review the brake assist characteristics and follow the Service Procedure if required. Brake Assist Characteristics: The booster gain will be increased during panic braking, which increases brake pressure and reduces pedal forces. The brakes will go to maximum pressure and the tires will chirp, sounding as if the tires are locking up (normal anti-lock brake control should be present). The pedal efforts will drop dramatically since the booster is providing maximum boost, which allows the pedal to travel with little effort; this is normal. It feels as if the pedal travels excessively, but the system is generating maximum brake pressure when this occurs; again, this is normal. When statically applying the brake pedal very hard, you may hear or feel (in the pedal) a slight click. This is the brake assist feature engaging inside the booster. The system will remain active as long as the brake pedal is depressed. NOTE MECHANICAL BRAKE ASSIST BOOSTERS ARE USED ON VEHICLES NOT EQUIPPED WITH RIDE STABILITY CONTROL. Vehicles equipped with Ride Stability Control receive an electronic active booster, which provides the brake assist feature by activating an electronic solenoid inside the booster. The active booster will provide similar pedal feedback when the feature is engaged, but the subtle clicks will not be present. SERVICE PROCEDURE To service, first advise the customer that the feature is there to help assist during panic braking. If the customer did not experience a panic braking situation, then the brake assist may have been unintended, on a mechanical brake assist system. Check for conditions that would lower the brake pedal height and activate the brake assist. 1. Check for air in the brake lines, repair any leaks and bleed the brake lines as necessary. Refer to the Workshop Manual, Section 206-00 General Procedures. 2. Inspect the brake linings for excessive wear, which can increase the pedal travel and engage the mechanical brake assist. Refer to the Workshop Manual, Section 206-00 Diagnosis and Testing. 3. Check the vacuum line between the booster and the manifold for obstructions or kinks. Repair as necessary. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2001 30 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > 05-26-21 > Dec > 05 > Brakes - Unintended Brake Assist Brake Bleeding: All Technical Service Bulletins Brakes - Unintended Brake Assist TSB 05-26-21 12/31/05 UNINTENDED BRAKE ASSIST FORD: 2003-2006 Expedition LINCOLN: 2003-2006 Navigator ISSUE Some 2003-2006 Expedition/Navigator may exhibit excessive pedal travel and/or low pedal effort, due to the mechanical or electronic brake assist being activated. ACTION Review the brake assist characteristics and follow the Service Procedure if required. Brake Assist Characteristics: The booster gain will be increased during panic braking, which increases brake pressure and reduces pedal forces. The brakes will go to maximum pressure and the tires will chirp, sounding as if the tires are locking up (normal anti-lock brake control should be present). The pedal efforts will drop dramatically since the booster is providing maximum boost, which allows the pedal to travel with little effort; this is normal. It feels as if the pedal travels excessively, but the system is generating maximum brake pressure when this occurs; again, this is normal. When statically applying the brake pedal very hard, you may hear or feel (in the pedal) a slight click. This is the brake assist feature engaging inside the booster. The system will remain active as long as the brake pedal is depressed. NOTE MECHANICAL BRAKE ASSIST BOOSTERS ARE USED ON VEHICLES NOT EQUIPPED WITH RIDE STABILITY CONTROL. Vehicles equipped with Ride Stability Control receive an electronic active booster, which provides the brake assist feature by activating an electronic solenoid inside the booster. The active booster will provide similar pedal feedback when the feature is engaged, but the subtle clicks will not be present. SERVICE PROCEDURE To service, first advise the customer that the feature is there to help assist during panic braking. If the customer did not experience a panic braking situation, then the brake assist may have been unintended, on a mechanical brake assist system. Check for conditions that would lower the brake pedal height and activate the brake assist. 1. Check for air in the brake lines, repair any leaks and bleed the brake lines as necessary. Refer to the Workshop Manual, Section 206-00 General Procedures. 2. Inspect the brake linings for excessive wear, which can increase the pedal travel and engage the mechanical brake assist. Refer to the Workshop Manual, Section 206-00 Diagnosis and Testing. 3. Check the vacuum line between the booster and the manifold for obstructions or kinks. Repair as necessary. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2001 30 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 6899 Brake Bleeding: By Symptom Technical Service Bulletin # 05-26-21 Date: 051231 Brakes - Unintended Brake Assist TSB 05-26-21 12/31/05 UNINTENDED BRAKE ASSIST FORD: 2003-2006 Expedition LINCOLN: 2003-2006 Navigator ISSUE Some 2003-2006 Expedition/Navigator may exhibit excessive pedal travel and/or low pedal effort, due to the mechanical or electronic brake assist being activated. ACTION Review the brake assist characteristics and follow the Service Procedure if required. Brake Assist Characteristics: The booster gain will be increased during panic braking, which increases brake pressure and reduces pedal forces. The brakes will go to maximum pressure and the tires will chirp, sounding as if the tires are locking up (normal anti-lock brake control should be present). The pedal efforts will drop dramatically since the booster is providing maximum boost, which allows the pedal to travel with little effort; this is normal. It feels as if the pedal travels excessively, but the system is generating maximum brake pressure when this occurs; again, this is normal. When statically applying the brake pedal very hard, you may hear or feel (in the pedal) a slight click. This is the brake assist feature engaging inside the booster. The system will remain active as long as the brake pedal is depressed. NOTE MECHANICAL BRAKE ASSIST BOOSTERS ARE USED ON VEHICLES NOT EQUIPPED WITH RIDE STABILITY CONTROL. Vehicles equipped with Ride Stability Control receive an electronic active booster, which provides the brake assist feature by activating an electronic solenoid inside the booster. The active booster will provide similar pedal feedback when the feature is engaged, but the subtle clicks will not be present. SERVICE PROCEDURE To service, first advise the customer that the feature is there to help assist during panic braking. If the customer did not experience a panic braking situation, then the brake assist may have been unintended, on a mechanical brake assist system. Check for conditions that would lower the brake pedal height and activate the brake assist. 1. Check for air in the brake lines, repair any leaks and bleed the brake lines as necessary. Refer to the Workshop Manual, Section 206-00 General Procedures. 2. Inspect the brake linings for excessive wear, which can increase the pedal travel and engage the mechanical brake assist. Refer to the Workshop Manual, Section 206-00 Diagnosis and Testing. 3. Check the vacuum line between the booster and the manifold for obstructions or kinks. Repair as necessary. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2001 30 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 6900 Disclaimer Technical Service Bulletin # 05-26-21 Date: 051231 Brakes - Unintended Brake Assist TSB 05-26-21 12/31/05 UNINTENDED BRAKE ASSIST FORD: 2003-2006 Expedition LINCOLN: 2003-2006 Navigator ISSUE Some 2003-2006 Expedition/Navigator may exhibit excessive pedal travel and/or low pedal effort, due to the mechanical or electronic brake assist being activated. ACTION Review the brake assist characteristics and follow the Service Procedure if required. Brake Assist Characteristics: The booster gain will be increased during panic braking, which increases brake pressure and reduces pedal forces. The brakes will go to maximum pressure and the tires will chirp, sounding as if the tires are locking up (normal anti-lock brake control should be present). The pedal efforts will drop dramatically since the booster is providing maximum boost, which allows the pedal to travel with little effort; this is normal. It feels as if the pedal travels excessively, but the system is generating maximum brake pressure when this occurs; again, this is normal. When statically applying the brake pedal very hard, you may hear or feel (in the pedal) a slight click. This is the brake assist feature engaging inside the booster. The system will remain active as long as the brake pedal is depressed. NOTE MECHANICAL BRAKE ASSIST BOOSTERS ARE USED ON VEHICLES NOT EQUIPPED WITH RIDE STABILITY CONTROL. Vehicles equipped with Ride Stability Control receive an electronic active booster, which provides the brake assist feature by activating an electronic solenoid inside the booster. The active booster will provide similar pedal feedback when the feature is engaged, but the subtle clicks will not be present. SERVICE PROCEDURE To service, first advise the customer that the feature is there to help assist during panic braking. If the customer did not experience a panic braking situation, then the brake assist may have been unintended, on a mechanical brake assist system. Check for conditions that would lower the brake pedal height and activate the brake assist. 1. Check for air in the brake lines, repair any leaks and bleed the brake lines as necessary. Refer to the Workshop Manual, Section 206-00 General Procedures. 2. Inspect the brake linings for excessive wear, which can increase the pedal travel and engage the mechanical brake assist. Refer to the Workshop Manual, Section 206-00 Diagnosis and Testing. 3. Check the vacuum line between the booster and the manifold for obstructions or kinks. Repair as necessary. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2001 30 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 6901 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) Brake Bleeding: Service and Repair Four Wheel Anti-Lock Brake System (4WABS) Four Wheel Anti-Lock Brake System (4WABS) WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse 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 diagnostic 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 bleeding removes 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 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. ^ Tighten to 16 Nm (12 ft. lbs.). 5. Repeat Steps 1 through 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. ^ Tighten to 16 Nm (12 ft. lbs.). 6. NOTE: Go to the Help menu in the diagnostic tool. Connect the diagnostic tool DCL cable adapter into the vehicle data link connector (DLC) under the dash and follow the diagnostic tool instructions. 7. Repeat the conventional bleed procedure as outlined in Steps 1 through 5. 8. If the brake pedal feels spongy, repeat the diagnostic tool service bleed procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 6904 Brake Bleeding: Service and Repair Gravity Gravity WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse 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: 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 brake fluid. 2. Bleed the rear disc brake calipers. ^ 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. ^ 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. ^ Tighten to 16 Nm (12 ft. lbs.). 4. Bleed the front disc brake calipers. ^ 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 clean brake fluid. ^ 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. ^ Tighten to 16 Nm (12 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 6905 Brake Bleeding: Service and Repair Manual Manual WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse 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. ^ Tighten to 16 Nm (12 ft. lbs.). 5. Repeat Steps 1 through 4 for the LH rear disc brake caliper. 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 clean 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. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 6906 9. Tighten the RH front disc brake caliper bleeder screw. ^ Tighten to 16 Nm (12 ft. lbs.). 10. Repeat Steps 6 through 9 for the LH front disc brake caliper bleeder screw. 11. If necessary, bleed the brake master cylinder. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 6907 Brake Bleeding: Service and Repair Pressure Pressure WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. ^ WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse 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 operation. 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. 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. ^ Tighten to 16 Nm (12 ft. lbs.). 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. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 6908 8. Fill the brake master cylinder reservoir and install the brake master cylinder filler cap. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 6909 Brake Bleeding: Service and Repair Four Wheel Anti-Lock Brake System (4WABS) Four Wheel Anti-Lock Brake System (4WABS) WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse 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 diagnostic 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 bleeding removes 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 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. ^ Tighten to 16 Nm (12 ft. lbs.). 5. Repeat Steps 1 through 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. ^ Tighten to 16 Nm (12 ft. lbs.). 6. NOTE: Go to the Help menu in the diagnostic tool. Connect the diagnostic tool DCL cable adapter into the vehicle data link connector (DLC) under the dash and follow the diagnostic tool instructions. 7. Repeat the conventional bleed procedure as outlined in Steps 1 through 5. 8. If the brake pedal feels spongy, repeat the diagnostic tool service bleed procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 6910 Gravity Gravity WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse 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: 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 brake fluid. 2. Bleed the rear disc brake calipers. ^ 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. ^ 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. ^ Tighten to 16 Nm (12 ft. lbs.). 4. Bleed the front disc brake calipers. ^ 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 clean brake fluid. ^ 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. ^ Tighten to 16 Nm (12 ft. lbs.). Manual Manual WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 6911 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. ^ Tighten to 16 Nm (12 ft. lbs.). 5. Repeat Steps 1 through 4 for the LH rear disc brake caliper. 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 clean 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. ^ Tighten to 16 Nm (12 ft. lbs.). 10. Repeat Steps 6 through 9 for the LH front disc brake caliper bleeder screw. 11. If necessary, bleed the brake master cylinder. Pressure Pressure WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. ^ WARNING: 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. Failure to follow these instructions may result in personal injury. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 6912 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 operation. 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. 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. ^ Tighten to 16 Nm (12 ft. lbs.). 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. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 6913 8. Fill the brake master cylinder reservoir and install the brake master cylinder filler cap. Brake System Bleeding Brake System Bleeding Special Tool(s) Material WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse 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. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 6914 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 brake fluid. 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. 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. ^ Tighten to 25 Nm (18 ft. lbs.). Master Cylinder, Bench Master Cylinder, Bench WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse 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. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 6915 1. Support the brake master cylinder body in a vise and fill the brake master cylinder reservoir with specified brake fluid. ^ Use clean brake fluid. 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. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair Brake Pedal Assy: Service and Repair Brake Pedal and Bracket NOTE: Adjustable brake pedal and bracket shown, fixed brake pedal and bracket similar. Removal and Installation Adjustable pedal vehicles 1. 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 all the way forward or all the way rearward. Disconnect the battery negative cable. For additional information, refer to Battery. 2. Remove the accelerator pedal-to-brake pedal cable. All vehicles 3. CAUTION: The booster pushrod must be installed with the pushrod offset, if present, pointing downward. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Page 6919 Remove the stoplight switch self-lock pin cover, the pin and slide the stoplight switch, booster push rod and the bushing off the brake pedal pin. 4. NOTE: Do not apply the brake pedal during the removal or installation of the speed control deactivation switch. Disconnect the electrical connector and turn the speed control deactivator switch counterclockwise to detach it from the brake pedal bracket. 5. Remove the bulkhead sound insulator. 6. Remove the 4 brake pedal bracket nuts. ^ To install, tighten to 22 Nm (16 ft. lbs.). 7. Remove the brake pedal bracket bolts and remove the brake pedal and bracket. ^ To install, tighten to 22 Nm (16 ft. lbs.). 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 06-12-5 > Jun > 06 > Brakes - Roughness or Shudder When Braking Brake Caliper: Customer Interest Brakes - Roughness or Shudder When Braking TSB 06-12-5 06/26/06 BRAKE SHUDDER FORD: 2004-2006 Expedition LINCOLN: 2004-2006 Navigator This article supersedes TSB 06-3-17 to add a production fix date. ISSUE Some 2004-2006 Expedition/Navigator vehicles built between 12/18/2003 and 03/01/2006 may experience repeat front brake roughness and / or shudder while braking. ACTION Determine if the vehicle has the old level rotors. If old level rotors, replace the front rotors and front caliper assemblies. If vehicle has new level rotors replace caliper assemblies and turn or replace the rotors as appropriate. SERVICE PROCEDURE 1. Check the build date of the front rotors. The build date is stamped on the inside of the rotor, between the fins (Figure 1). If the rotor date code is before 4H23 (4=2004, H=August, 23=23rd), replace the front rotors and front caliper assemblies. Refer to Workshop Manual, Section 206-03 for front rotor and caliper replacement procedure. NOTE REPLACE CALIPERS WITH NEW SERVICE FIX CALIPER ASSEMBLIES BY REMOVING THE CALIPERS AT THE KNUCKLES. THE SERVICE REPLACEMENT CALIPERS WILL BE PRE-ASSEMBLED WITH ANCHOR, SPRINGS, AND PADS. THE CALIPERS SHOULD BE INSTALLED AS A UNIT WITHOUT DISASSEMBLY. 2. If the rotor date code is 4H23 or greater replace the caliper assemblies and use the on-the-car brake lathe to turn the rotor if still within minimum thickness specification. If rotor is beyond machinable thickness, replace the front rotors. NOTE DUE TO THE PISTON SEAL ROLLBACK DESIGN CHANGE WITHIN THE CALIPER, THE PEDAL TRAVEL MAY INCREASE APPROXIMATELY 9/32" (7 MM). THIS INCREASE IN TRAVEL IS CONSIDERED NORMAL. THIS CHANGE DOES NOT AFFECT BRAKE STOPPING DISTANCE AND/OR BRAKE EFFECTIVENESS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 06-12-5 > Jun > 06 > Brakes - Roughness or Shudder When Braking > Page 6929 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061205A 2004-2006 0.9 Hr. Expedition/Navigator: Replace Front Brake Calipers, Replace Rotors (Do Not Use With 2000A, 2001BFA, 2001B2P, 2001B2PT, 2001B5FT, 2001B8F, 2001B8FT) 061205B 2004-2006 1.5 Hrs. Expedition/Navigator: Replace Front Brake Calipers, Refinish Rotors (Do Not Use With 2000A, 2001BFA, 2001B2P, 2001BPT, 2001B5FT, 2001B8F, 2001B8FT) DEALER CODING CONDITION BASIC PART NO. CODE 2B120 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 06-12-5 > Jun > 06 > Brakes - Roughness or Shudder When Braking Brake Caliper: All Technical Service Bulletins Brakes - Roughness or Shudder When Braking TSB 06-12-5 06/26/06 BRAKE SHUDDER FORD: 2004-2006 Expedition LINCOLN: 2004-2006 Navigator This article supersedes TSB 06-3-17 to add a production fix date. ISSUE Some 2004-2006 Expedition/Navigator vehicles built between 12/18/2003 and 03/01/2006 may experience repeat front brake roughness and / or shudder while braking. ACTION Determine if the vehicle has the old level rotors. If old level rotors, replace the front rotors and front caliper assemblies. If vehicle has new level rotors replace caliper assemblies and turn or replace the rotors as appropriate. SERVICE PROCEDURE 1. Check the build date of the front rotors. The build date is stamped on the inside of the rotor, between the fins (Figure 1). If the rotor date code is before 4H23 (4=2004, H=August, 23=23rd), replace the front rotors and front caliper assemblies. Refer to Workshop Manual, Section 206-03 for front rotor and caliper replacement procedure. NOTE REPLACE CALIPERS WITH NEW SERVICE FIX CALIPER ASSEMBLIES BY REMOVING THE CALIPERS AT THE KNUCKLES. THE SERVICE REPLACEMENT CALIPERS WILL BE PRE-ASSEMBLED WITH ANCHOR, SPRINGS, AND PADS. THE CALIPERS SHOULD BE INSTALLED AS A UNIT WITHOUT DISASSEMBLY. 2. If the rotor date code is 4H23 or greater replace the caliper assemblies and use the on-the-car brake lathe to turn the rotor if still within minimum thickness specification. If rotor is beyond machinable thickness, replace the front rotors. NOTE DUE TO THE PISTON SEAL ROLLBACK DESIGN CHANGE WITHIN THE CALIPER, THE PEDAL TRAVEL MAY INCREASE APPROXIMATELY 9/32" (7 MM). THIS INCREASE IN TRAVEL IS CONSIDERED NORMAL. THIS CHANGE DOES NOT AFFECT BRAKE STOPPING DISTANCE AND/OR BRAKE EFFECTIVENESS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 06-12-5 > Jun > 06 > Brakes - Roughness or Shudder When Braking > Page 6935 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061205A 2004-2006 0.9 Hr. Expedition/Navigator: Replace Front Brake Calipers, Replace Rotors (Do Not Use With 2000A, 2001BFA, 2001B2P, 2001B2PT, 2001B5FT, 2001B8F, 2001B8FT) 061205B 2004-2006 1.5 Hrs. Expedition/Navigator: Replace Front Brake Calipers, Refinish Rotors (Do Not Use With 2000A, 2001BFA, 2001B2P, 2001BPT, 2001B5FT, 2001B8F, 2001B8FT) DEALER CODING CONDITION BASIC PART NO. CODE 2B120 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Page 6936 General Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front Brake Caliper: Service and Repair Caliper Removal and Installation, Front Brake Caliper Material Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6939 Front Brake Disc System Front Brake Disc System Removal and Installation Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6940 WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. 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. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the brake pads. 3. CAUTION: Install a new lining if it is worn to or past the specified thickness above the metal backing plate or rivets. Install new pads in complete axle sets. Inspect the pads for wear or contamination. 4. Disconnect the front brake hose. ^ Use new copper washers to connect the front brake hose. ^ To install, tighten to 35 Nm (26 ft. lbs.). 5. Remove the disc brake caliper bolts. ^ To install, tighten to 55 Nm (41 ft. lbs.). 6. Inspect the brake disc and resurface or install a new brake disc as necessary. 7. Inspect the disc brake caliper for leaks. ^ If leaks are found, the brake caliper must be disassembled. 8. Bleed the brake system. 9. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6941 Brake Caliper: Service and Repair Caliper Removal and Installation, Rear Brake Caliper Material Rear Brake Disc Components Removal and Installation WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6942 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. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. 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. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the brake hose flow bolt and disconnect the hose. ^ Remove and discard the copper washers. ^ To install, tighten to 35 Nm (26 ft. lbs.). 3. Remove the brake pads. 4. Inspect the disc brake caliper for leaks. ^ If leaks are found, disassembly is required. 5. Bleed the brake system. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6943 Brake Caliper: Service and Repair Brake Caliper Anchor Plate, Rear Brake Caliper Anchor Plate Material Rear Brake Disc Components Removal and Installation WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6944 brakes inoperative. Failure to follow these instructions may result in personal injury. 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. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. Check the brake fluid level in the brake master cylinder reservoir. ^ If required, remove the fluid until the brake master cylinder reservoir is half full. 2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 3. Using the large C-clamp, compress the pistons into the caliper housing. 4. CAUTION: Do not allow the caliper to hang from the brake hose or damage to the hose can occur. Remove the 2 brake caliper guide pin bolts and position the caliper aside. ^ Support the caliper using mechanic's wire. ^ To install, tighten to 35 Nm (26 ft. lbs.). 5. Remove the brake pads from the caliper anchor plate. 6. Remove the 2 brake caliper anchor plate bolts and the brake caliper anchor plate. ^ To install, tighten to 190 Nm (140 ft. lbs.). 7. To install, reverse the removal procedure. ^ Test the brakes for normal operation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6945 Brake Caliper: Service and Repair Brake Caliper Anchor Plate, Front Brake Caliper Anchor Plate Removal Front Brake Disc System Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6946 Front Brake Disc System WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. If necessary, using a suitable suction device, remove the brake fluid in the master cylinder reservoir until it is half filled. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. 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. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 3. CAUTION: Install new brake pads if the lining(s) are worn to or past the specified thickness above the metal backing plate or rivets. Install new pads in complete axle sets. Inspect the brake pads for wear or contamination. ^ Install new pads as necessary. 4. CAUTION: If the anchor housing spring is to be reused, do not force the anchor housing spring off the brake caliper or damage to the spring can occur. Do not install a damaged anchor housing spring. Remove the anchor housing spring. 5. NOTE: The LH side anchor housing spring must be installed with the 2-tabbed end in the upper brake caliper cavity. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6947 For the LH brake caliper, release the lower portion of the anchor housing spring. ^ Apply force at the center of the anchor housing spring and pull outward at the bottom of the anchor housing spring to remove it from the lower brake caliper cavity. 6. Rotate the spring upward then remove it from the brake caliper. 7. NOTE: The RH anchor housing spring must be installed with the 2-tabbed end in the lower brake caliper cavity. The illustration below shows the anchor housing spring end with 2 tabs. For RH brake caliper, release the upper portion of the anchor housing spring. ^ Apply force at the center of the anchor housing spring and pull outward at the top of the anchor housing spring to remove it from the upper brake caliper cavity. 8. Rotate the spring downward then remove it from the brake caliper. 9. NOTE: Do not allow the brake caliper to hang from the brake hose or damage to the hose can occur. Remove the guide pins and position the caliper aside. ^ Remove the zero-drag spring. ^ Remove and discard the brake caliper-to-anchor plate guide pins and boots. 10. Remove the brake caliper anchor plate bolts. 11. Remove the brake caliper anchor plate. Installation 1. Install the brake caliper anchor plate and bolts. ^ Tighten to 200 Nm (148 ft. lbs.). 2. Using brake parts cleaner, clean the inner surfaces of the brake caliper where the brake pads attach. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6948 3. Install new brake hardware as follows: ^ Install the guide pin bushings into the caliper bores. ^ Apply grease to the inside of the guide pin bushing. Do not apply grease to the guide pin threads. ^ Push the guide pins into the bushing. 4. Install the inboard brake pad into the brake caliper. 5. Remove the protective paper from the outboard brake pad and install it into the brake caliper. 6. Install the brake caliper on the brake disc. 7. Install the guide pins and install the dust caps. ^ Tighten to 55 Nm (41 ft. lbs.). ^ Install the guide pin boots. 8. Install the zero-drag spring. NOTE: If present, the 2-tabbed end of the anchor housing spring must be installed first. 9. Install the anchor housing spring. 1 Insert the tab of the anchor housing spring into the brake caliper cavity. 2 Twist the tab into the brake caliper cavity (LH side-upper brake caliper cavity/RH side-lower brake caliper cavity). 10. Rotate the anchor housing spring and position the upper portion onto the anchor plate. 11. Position the other anchor housing spring portion onto the brake caliper anchor plate. 12. Push down and inward until the upper and lower ends of the anchor housing spring are latched and seated in the brake caliper cavities. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6949 13. NOTE: The latch MUST be positioned as shown. Verify that the anchor housing spring is correctly latched. 14. Apply the brake several times to verify correct brake operation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6950 Brake Caliper: Service and Repair Caliper Removal and Installation, Front Brake Caliper Material Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6951 Front Brake Disc System Front Brake Disc System Removal and Installation Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6952 WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. 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. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the brake pads. 3. CAUTION: Install a new lining if it is worn to or past the specified thickness above the metal backing plate or rivets. Install new pads in complete axle sets. Inspect the pads for wear or contamination. 4. Disconnect the front brake hose. ^ Use new copper washers to connect the front brake hose. ^ To install, tighten to 35 Nm (26 ft. lbs.). 5. Remove the disc brake caliper bolts. ^ To install, tighten to 55 Nm (41 ft. lbs.). 6. Inspect the brake disc and resurface or install a new brake disc as necessary. 7. Inspect the disc brake caliper for leaks. ^ If leaks are found, the brake caliper must be disassembled. 8. Bleed the brake system. 9. To install, reverse the removal procedure. Caliper Removal and Installation, Rear Brake Caliper Material Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6953 Rear Brake Disc Components Removal and Installation WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. 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. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the brake hose flow bolt and disconnect the hose. ^ Remove and discard the copper washers. ^ To install, tighten to 35 Nm (26 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6954 3. Remove the brake pads. 4. Inspect the disc brake caliper for leaks. ^ If leaks are found, disassembly is required. 5. Bleed the brake system. 6. To install, reverse the removal procedure. Brake Caliper Anchor Plate, Rear Brake Caliper Anchor Plate Material Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6955 Rear Brake Disc Components Removal and Installation WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. Check the brake fluid level in the brake master cylinder reservoir. ^ If required, remove the fluid until the brake master cylinder reservoir is half full. 2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 3. Using the large C-clamp, compress the pistons into the caliper housing. 4. CAUTION: Do not allow the caliper to hang from the brake hose or damage to the hose can occur. Remove the 2 brake caliper guide pin bolts and position the caliper aside. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6956 ^ Support the caliper using mechanic's wire. ^ To install, tighten to 35 Nm (26 ft. lbs.). 5. Remove the brake pads from the caliper anchor plate. 6. Remove the 2 brake caliper anchor plate bolts and the brake caliper anchor plate. ^ To install, tighten to 190 Nm (140 ft. lbs.). 7. To install, reverse the removal procedure. ^ Test the brakes for normal operation. Brake Caliper Anchor Plate, Front Brake Caliper Anchor Plate Removal Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6957 Front Brake Disc System Front Brake Disc System WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. If necessary, using a suitable suction device, remove the brake fluid in the master cylinder reservoir until it is half filled. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. 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. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 3. CAUTION: Install new brake pads if the lining(s) are worn to or past the specified thickness above the metal backing plate or rivets. Install new pads in complete axle sets. Inspect the brake pads for wear or contamination. ^ Install new pads as necessary. 4. CAUTION: If the anchor housing spring is to be reused, do not force the anchor housing spring off the brake caliper or damage to the spring can occur. Do not install a damaged anchor housing spring. Remove the anchor housing spring. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6958 5. NOTE: The LH side anchor housing spring must be installed with the 2-tabbed end in the upper brake caliper cavity. For the LH brake caliper, release the lower portion of the anchor housing spring. ^ Apply force at the center of the anchor housing spring and pull outward at the bottom of the anchor housing spring to remove it from the lower brake caliper cavity. 6. Rotate the spring upward then remove it from the brake caliper. 7. NOTE: The RH anchor housing spring must be installed with the 2-tabbed end in the lower brake caliper cavity. The illustration below shows the anchor housing spring end with 2 tabs. For RH brake caliper, release the upper portion of the anchor housing spring. ^ Apply force at the center of the anchor housing spring and pull outward at the top of the anchor housing spring to remove it from the upper brake caliper cavity. 8. Rotate the spring downward then remove it from the brake caliper. 9. NOTE: Do not allow the brake caliper to hang from the brake hose or damage to the hose can occur. Remove the guide pins and position the caliper aside. ^ Remove the zero-drag spring. ^ Remove and discard the brake caliper-to-anchor plate guide pins and boots. 10. Remove the brake caliper anchor plate bolts. 11. Remove the brake caliper anchor plate. Installation 1. Install the brake caliper anchor plate and bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6959 ^ Tighten to 200 Nm (148 ft. lbs.). 2. Using brake parts cleaner, clean the inner surfaces of the brake caliper where the brake pads attach. 3. Install new brake hardware as follows: ^ Install the guide pin bushings into the caliper bores. ^ Apply grease to the inside of the guide pin bushing. Do not apply grease to the guide pin threads. ^ Push the guide pins into the bushing. 4. Install the inboard brake pad into the brake caliper. 5. Remove the protective paper from the outboard brake pad and install it into the brake caliper. 6. Install the brake caliper on the brake disc. 7. Install the guide pins and install the dust caps. ^ Tighten to 55 Nm (41 ft. lbs.). ^ Install the guide pin boots. 8. Install the zero-drag spring. NOTE: If present, the 2-tabbed end of the anchor housing spring must be installed first. 9. Install the anchor housing spring. 1 Insert the tab of the anchor housing spring into the brake caliper cavity. 2 Twist the tab into the brake caliper cavity (LH side-upper brake caliper cavity/RH side-lower brake caliper cavity). 10. Rotate the anchor housing spring and position the upper portion onto the anchor plate. 11. Position the other anchor housing spring portion onto the brake caliper anchor plate. 12. Push down and inward until the upper and lower ends of the anchor housing spring are latched and seated in the brake caliper cavities. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6960 13. NOTE: The latch MUST be positioned as shown. Verify that the anchor housing spring is correctly latched. 14. Apply the brake several times to verify correct brake operation. Caliper Disassembly and Assembly, Front Brake Caliper Material Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6961 Front Brake Disc System Front Brake Disc System Disassembly Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6962 WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. Remove the brake caliper. 2. Apply low air pressure to the fluid port in the brake caliper. 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 brake caliper to force out the caliper pistons. 3 Remove the block of wood and the caliper pistons. 3. Remove the caliper piston seals and boots. 4. Inspect the caliper bores for scoring or corrosion. If scoring and corrosion exist, install a new brake caliper assembly. Assembly 1. Lubricate the caliper piston boots, caliper pistons, caliper piston seals and caliper bores with DOT 3 brake fluid. 2. Install the caliper pistons into the caliper bores. 1 Install the piston seals onto the caliper pistons. 2 Install the caliper piston boots onto the caliper pistons. 3 Insert the caliper pistons into the caliper bores. 4 Press the caliper pistons into the caliper bores. 3. Install the brake caliper. Caliper Disassembly and Assembly, Rear Brake Caliper Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6963 Special Tool(s) Material Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6964 Rear Brake Disc Components Disassembly WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. 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 piston. ^ Place a block of wood between the caliper bridge and the caliper piston. ^ Apply low air pressure to the fluid port in the disc brake caliper. ^ Force out the caliper piston to the block of wood. ^ Remove the block of wood and the caliper piston. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6965 5. NOTE: Do not hone the cylinder bore. Caliper pistons are not available for honed cylinder bores. If the disc brake caliper cylinder bore or piston is excessively scored or corroded, install a new disc brake caliper. Remove and discard the piston seal and dust boot. Assembly CAUTION: Never reuse the piston seal or dust boot. 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. 1. Lubricate these items with brake fluid: ^ Cylinder bore. ^ Piston seal. ^ Caliper piston. ^ Dust boot. 2. Install the piston seal. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 6966 3. Using the special tools, install the dust boot. 4. CAUTION: Be careful not to damage or dislodge the piston seal. CAUTION: Insert the caliper piston squarely into the caliper bore. Install the caliper piston. ^ Place the brake caliper in a vise. ^ Place the piston squarely against the dust boot. ^ While applying shop air into the brake caliper, push the piston squarely into the brake caliper bore. 5. Install the disc brake caliper. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest for Brake Pad: > 05-26-21 > Dec > 05 > Brakes - Unintended Brake Assist Brake Pad: Customer Interest Brakes - Unintended Brake Assist TSB 05-26-21 12/31/05 UNINTENDED BRAKE ASSIST FORD: 2003-2006 Expedition LINCOLN: 2003-2006 Navigator ISSUE Some 2003-2006 Expedition/Navigator may exhibit excessive pedal travel and/or low pedal effort, due to the mechanical or electronic brake assist being activated. ACTION Review the brake assist characteristics and follow the Service Procedure if required. Brake Assist Characteristics: The booster gain will be increased during panic braking, which increases brake pressure and reduces pedal forces. The brakes will go to maximum pressure and the tires will chirp, sounding as if the tires are locking up (normal anti-lock brake control should be present). The pedal efforts will drop dramatically since the booster is providing maximum boost, which allows the pedal to travel with little effort; this is normal. It feels as if the pedal travels excessively, but the system is generating maximum brake pressure when this occurs; again, this is normal. When statically applying the brake pedal very hard, you may hear or feel (in the pedal) a slight click. This is the brake assist feature engaging inside the booster. The system will remain active as long as the brake pedal is depressed. NOTE MECHANICAL BRAKE ASSIST BOOSTERS ARE USED ON VEHICLES NOT EQUIPPED WITH RIDE STABILITY CONTROL. Vehicles equipped with Ride Stability Control receive an electronic active booster, which provides the brake assist feature by activating an electronic solenoid inside the booster. The active booster will provide similar pedal feedback when the feature is engaged, but the subtle clicks will not be present. SERVICE PROCEDURE To service, first advise the customer that the feature is there to help assist during panic braking. If the customer did not experience a panic braking situation, then the brake assist may have been unintended, on a mechanical brake assist system. Check for conditions that would lower the brake pedal height and activate the brake assist. 1. Check for air in the brake lines, repair any leaks and bleed the brake lines as necessary. Refer to the Workshop Manual, Section 206-00 General Procedures. 2. Inspect the brake linings for excessive wear, which can increase the pedal travel and engage the mechanical brake assist. Refer to the Workshop Manual, Section 206-00 Diagnosis and Testing. 3. Check the vacuum line between the booster and the manifold for obstructions or kinks. Repair as necessary. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2001 30 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 05-26-21 > Dec > 05 > Brakes - Unintended Brake Assist Brake Pad: All Technical Service Bulletins Brakes - Unintended Brake Assist TSB 05-26-21 12/31/05 UNINTENDED BRAKE ASSIST FORD: 2003-2006 Expedition LINCOLN: 2003-2006 Navigator ISSUE Some 2003-2006 Expedition/Navigator may exhibit excessive pedal travel and/or low pedal effort, due to the mechanical or electronic brake assist being activated. ACTION Review the brake assist characteristics and follow the Service Procedure if required. Brake Assist Characteristics: The booster gain will be increased during panic braking, which increases brake pressure and reduces pedal forces. The brakes will go to maximum pressure and the tires will chirp, sounding as if the tires are locking up (normal anti-lock brake control should be present). The pedal efforts will drop dramatically since the booster is providing maximum boost, which allows the pedal to travel with little effort; this is normal. It feels as if the pedal travels excessively, but the system is generating maximum brake pressure when this occurs; again, this is normal. When statically applying the brake pedal very hard, you may hear or feel (in the pedal) a slight click. This is the brake assist feature engaging inside the booster. The system will remain active as long as the brake pedal is depressed. NOTE MECHANICAL BRAKE ASSIST BOOSTERS ARE USED ON VEHICLES NOT EQUIPPED WITH RIDE STABILITY CONTROL. Vehicles equipped with Ride Stability Control receive an electronic active booster, which provides the brake assist feature by activating an electronic solenoid inside the booster. The active booster will provide similar pedal feedback when the feature is engaged, but the subtle clicks will not be present. SERVICE PROCEDURE To service, first advise the customer that the feature is there to help assist during panic braking. If the customer did not experience a panic braking situation, then the brake assist may have been unintended, on a mechanical brake assist system. Check for conditions that would lower the brake pedal height and activate the brake assist. 1. Check for air in the brake lines, repair any leaks and bleed the brake lines as necessary. Refer to the Workshop Manual, Section 206-00 General Procedures. 2. Inspect the brake linings for excessive wear, which can increase the pedal travel and engage the mechanical brake assist. Refer to the Workshop Manual, Section 206-00 Diagnosis and Testing. 3. Check the vacuum line between the booster and the manifold for obstructions or kinks. Repair as necessary. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2001 30 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Page 6980 Brake Pad: Specifications Brake Pads Minimum brake pad thickness ............................................................................................................................................................ 2.0 mm (0.079 inch) Maximum brake pad thickness variation (pad-to-pad) ........................................................................................................................ 2.0 mm (0.079 inch) Maximum brake pad taper wear (in any direction) ............................................................................................................................. 3.0 mm (0.118 inch) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front Brake Pad: Service and Repair Front Brake Pads Material Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6983 Front Brake Disc System Front Brake Disc System Removal Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6984 WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. If necessary, using a suitable suction device, remove the brake fluid in the master cylinder reservoir until it is half filled. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. 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. With the vehicle in NEUTRAL, position it on a hoist. For additional information, Maintenance/Service and Repair. 3. CAUTION: Install new brake pads if the lining(s) are worn to or past the specified thickness above the metal backing plate or rivets. Install new pads in complete axle sets. Inspect the brake pads for wear or contamination and install new pads as necessary. 4. CAUTION: If the anchor housing spring is to be reused, do not force the anchor housing spring off the brake caliper or damage to the spring can occur. Do not install a damaged anchor housing spring. Remove the anchor housing spring. 5. NOTE: The LH side anchor housing spring must be installed with the 2-tabbed end in the upper brake caliper cavity. For the LH brake caliper, release the lower portion of the anchor housing spring. ^ Apply force at the center of the anchor housing spring and pull outward at the bottom of the anchor housing spring to remove it from the lower brake caliper cavity. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6985 6. Rotate the spring upward then remove it from the brake caliper. 7. NOTE: The RH anchor housing spring must be installed with the 2-tabbed end in the lower brake caliper cavity. The illustration below shows the anchor housing spring end with 2 tabs. For RH brake caliper, release the upper portion of the anchor housing spring. ^ Apply force at the center of the anchor housing spring and pull outward at the top of the anchor housing spring to remove it from the upper brake caliper cavity. 8. Rotate the spring downward then remove it from the brake caliper. 9. NOTE: Do not allow the brake caliper to hang from the brake hose or damage to the hose can occur. Remove the guide pins and position the caliper aside. ^ Remove the zero-drag spring. ^ Remove and discard the brake caliper-to-anchor plate guide pins and boots. 10. Remove the brake pads from the brake caliper. 11. NOTE: Use a wood block or a used brake pad to protect the brake caliper piston boots. Compress the brake caliper pistons. 12. Inspect the brake disc and resurface or install a new brake disc as necessary. Installation 1. Using brake parts cleaner, clean the inner surfaces of the brake caliper where the brake pads attach. 2. Install new brake hardware as follows: ^ Install the guide pin bushings into the caliper bores. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6986 ^ Apply grease to the inside of the guide pin bushing. Do not apply grease to the guide pin threads. ^ Push the guide pins into the bushing. 3. Install the inboard brake pad into the brake caliper. 4. Remove the protective paper from the outboard brake pad and install it into the brake caliper. 5. Install the brake caliper on the brake disc. 6. Install the guide pins and install the dust caps. ^ Tighten to 55 Nm (41 ft. lbs.). ^ Install the guide pin boots. 7. Install the zero-drag spring. NOTE: If present, the 2-tabbed end of the anchor housing spring must be installed first. 8. Install the anchor housing spring. 1 Insert the tab of the anchor housing spring into the brake caliper cavity. 2 Twist the tab into the brake caliper cavity (LH side-upper brake caliper cavity/RH side-lower brake caliper cavity). 9. Rotate the anchor housing spring and position the upper portion onto the anchor plate. 10. Position the other anchor housing spring portion onto the brake caliper anchor plate. 11. Push down and inward until the upper and lower ends of the anchor housing spring are latched and seated in the brake caliper cavities. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6987 12. NOTE: The latch MUST be positioned as shown. Verify that the anchor housing spring is correctly latched. 13. Apply the brake several times to verify correct brake operation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6988 Brake Pad: Service and Repair Rear Brake Pads Material Rear Brake Disc Components Removal WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6989 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. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. Using a clear suction device, remove brake fluid in the master cylinder reservoir until the reservoir is half full. 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. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 3. CAUTION: Install new pads if the lining(s) are worn to or past the specified thickness above the metal backing plate. Install new pads in complete axle sets. Inspect the brake pads for wear or contamination and install new pads as necessary. 4. Remove the anchor housing spring. ^ Squeeze at the center of the spring until it unlatches from the brake caliper at both ends. ^ Rotate the spring, then remove it from the caliper housing. 5. CAUTION: Do not allow the brake caliper to hang by the flexible brake hose or damage to the hose can occur. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6990 Remove the caps and the 2 brake caliper guide pin bolts and position the caliper aside. ^ Support the caliper using mechanic's wire. 6. Remove the brake pads from the caliper. 7. Using a suitable clamp, press the piston into the caliper. 8. Inspect the brake disc and resurface or install a new brake disc as necessary. Installation 1. Install the brake pads to the caliper. 2. Position the caliper onto the anchor plate and install the 2 brake caliper guide pin bolts. ^ To install, tighten to 35 Nm (26 ft. lbs.). 3. Install the anchor housing spring. 1 Insert the upper anchor housing spring end into the brake caliper cavity. 2 Rotate the anchor housing spring and position the lower arm onto the anchor plate. 4. Position the upper arm onto the anchor plate, then press down and inward until it is correctly seated and latched into the brake caliper cavities. 5. NOTE: The latch MUST be positioned as shown. Verify that the anchor housing spring is correctly latched. 6. Apply the brake several times to verify correct brake operation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Customer Interest for Brake Rotor/Disc: > 06-12-5 > Jun > 06 > Brakes - Roughness or Shudder When Braking Brake Rotor/Disc: Customer Interest Brakes - Roughness or Shudder When Braking TSB 06-12-5 06/26/06 BRAKE SHUDDER FORD: 2004-2006 Expedition LINCOLN: 2004-2006 Navigator This article supersedes TSB 06-3-17 to add a production fix date. ISSUE Some 2004-2006 Expedition/Navigator vehicles built between 12/18/2003 and 03/01/2006 may experience repeat front brake roughness and / or shudder while braking. ACTION Determine if the vehicle has the old level rotors. If old level rotors, replace the front rotors and front caliper assemblies. If vehicle has new level rotors replace caliper assemblies and turn or replace the rotors as appropriate. SERVICE PROCEDURE 1. Check the build date of the front rotors. The build date is stamped on the inside of the rotor, between the fins (Figure 1). If the rotor date code is before 4H23 (4=2004, H=August, 23=23rd), replace the front rotors and front caliper assemblies. Refer to Workshop Manual, Section 206-03 for front rotor and caliper replacement procedure. NOTE REPLACE CALIPERS WITH NEW SERVICE FIX CALIPER ASSEMBLIES BY REMOVING THE CALIPERS AT THE KNUCKLES. THE SERVICE REPLACEMENT CALIPERS WILL BE PRE-ASSEMBLED WITH ANCHOR, SPRINGS, AND PADS. THE CALIPERS SHOULD BE INSTALLED AS A UNIT WITHOUT DISASSEMBLY. 2. If the rotor date code is 4H23 or greater replace the caliper assemblies and use the on-the-car brake lathe to turn the rotor if still within minimum thickness specification. If rotor is beyond machinable thickness, replace the front rotors. NOTE DUE TO THE PISTON SEAL ROLLBACK DESIGN CHANGE WITHIN THE CALIPER, THE PEDAL TRAVEL MAY INCREASE APPROXIMATELY 9/32" (7 MM). THIS INCREASE IN TRAVEL IS CONSIDERED NORMAL. THIS CHANGE DOES NOT AFFECT BRAKE STOPPING DISTANCE AND/OR BRAKE EFFECTIVENESS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Customer Interest for Brake Rotor/Disc: > 06-12-5 > Jun > 06 > Brakes - Roughness or Shudder When Braking > Page 6999 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061205A 2004-2006 0.9 Hr. Expedition/Navigator: Replace Front Brake Calipers, Replace Rotors (Do Not Use With 2000A, 2001BFA, 2001B2P, 2001B2PT, 2001B5FT, 2001B8F, 2001B8FT) 061205B 2004-2006 1.5 Hrs. Expedition/Navigator: Replace Front Brake Calipers, Refinish Rotors (Do Not Use With 2000A, 2001BFA, 2001B2P, 2001BPT, 2001B5FT, 2001B8F, 2001B8FT) DEALER CODING CONDITION BASIC PART NO. CODE 2B120 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 06-12-5 > Jun > 06 > Brakes Roughness or Shudder When Braking Brake Rotor/Disc: All Technical Service Bulletins Brakes - Roughness or Shudder When Braking TSB 06-12-5 06/26/06 BRAKE SHUDDER FORD: 2004-2006 Expedition LINCOLN: 2004-2006 Navigator This article supersedes TSB 06-3-17 to add a production fix date. ISSUE Some 2004-2006 Expedition/Navigator vehicles built between 12/18/2003 and 03/01/2006 may experience repeat front brake roughness and / or shudder while braking. ACTION Determine if the vehicle has the old level rotors. If old level rotors, replace the front rotors and front caliper assemblies. If vehicle has new level rotors replace caliper assemblies and turn or replace the rotors as appropriate. SERVICE PROCEDURE 1. Check the build date of the front rotors. The build date is stamped on the inside of the rotor, between the fins (Figure 1). If the rotor date code is before 4H23 (4=2004, H=August, 23=23rd), replace the front rotors and front caliper assemblies. Refer to Workshop Manual, Section 206-03 for front rotor and caliper replacement procedure. NOTE REPLACE CALIPERS WITH NEW SERVICE FIX CALIPER ASSEMBLIES BY REMOVING THE CALIPERS AT THE KNUCKLES. THE SERVICE REPLACEMENT CALIPERS WILL BE PRE-ASSEMBLED WITH ANCHOR, SPRINGS, AND PADS. THE CALIPERS SHOULD BE INSTALLED AS A UNIT WITHOUT DISASSEMBLY. 2. If the rotor date code is 4H23 or greater replace the caliper assemblies and use the on-the-car brake lathe to turn the rotor if still within minimum thickness specification. If rotor is beyond machinable thickness, replace the front rotors. NOTE DUE TO THE PISTON SEAL ROLLBACK DESIGN CHANGE WITHIN THE CALIPER, THE PEDAL TRAVEL MAY INCREASE APPROXIMATELY 9/32" (7 MM). THIS INCREASE IN TRAVEL IS CONSIDERED NORMAL. THIS CHANGE DOES NOT AFFECT BRAKE STOPPING DISTANCE AND/OR BRAKE EFFECTIVENESS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 06-12-5 > Jun > 06 > Brakes Roughness or Shudder When Braking > Page 7005 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061205A 2004-2006 0.9 Hr. Expedition/Navigator: Replace Front Brake Calipers, Replace Rotors (Do Not Use With 2000A, 2001BFA, 2001B2P, 2001B2PT, 2001B5FT, 2001B8F, 2001B8FT) 061205B 2004-2006 1.5 Hrs. Expedition/Navigator: Replace Front Brake Calipers, Refinish Rotors (Do Not Use With 2000A, 2001BFA, 2001B2P, 2001BPT, 2001B5FT, 2001B8F, 2001B8FT) DEALER CODING CONDITION BASIC PART NO. CODE 2B120 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 7006 Brake Rotor/Disc: Specifications Brake Disc Minimum disc thickness Front .................................................................................................................................................... ........................................ 27.0 mm (1.06 inch) Rear ........................................................................... .................................................................................................................. 19.0 mm (0.74 inch) Minimum thickness to machine Front .................................................................................................................................................... ........................................ 28.3 mm (1.11 inch) Rear ........................................................................... .................................................................................................................. 19.6 mm (0.77 inch) Maximum disc runout Rear ..................................................................................................................................................... .................................... 0.025 mm (0.001 inch) Maximum disc thickness variation Rear ..................................................................................................................................................... .................................... 0.013 mm (0.005 inch) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Disc Machining Brake Rotor/Disc: Service and Repair Brake Disc Machining Brake Disc Machining Special Tool(s) Material CAUTION: Do not use a bench lathe to machine the brake discs. NOTE: Read the entire operating manual and view the video shipped with the lathe before installing, operating, or repairing the lathe. NOTE: If the thickness of the brake disc is less than the minimum thickness to machine specification, install a new brake disc. This will make sure that the brake disc will be above minimum thickness after machining. NOTE: Do not machine new brake discs. NOTE: Lateral runout and disc thickness variation measurements are not required because correct adjustment of the on-vehicle brake lathe will make sure that these dimensions are within specifications. 1. NOTE: It is not necessary to disconnect the brake line from the brake caliper. Position the brake caliper and brake caliper anchor bracket aside. 2. For vehicles with a 2-piece brake disc and hub assembly: 1 Mark the brake disc and the wheel stud for correct indexing during re-assembly. 2 Remove the brake disc from the hub. 3 CAUTION: Do not use an abrasive sanding disc since it will remove paint or other protective finishes from the wheel or metal from the mounting surfaces, adversely affecting corrosion protection and brake disc lateral runout. Remove corrosion from the wheel mounting surface, both disc mounting surfaces, and hub mounting surface. 4 Align the match marks and install the brake disc on the hub. 3. Machine the brake disc using an on-car brake lathe. 1 Install the hub adapter and silencer belt, if necessary. 2 Install the cutting lathe. 3 If the lathe is not self adjusting, adjust the lathe oscillation using a dial indicator. Total indicated reading (TIR) target is 0.000 mm (0.000 inch), maximum is 0.08 mm (0.003 inch). 4 Center the cutting head, adjust the cutting bits, and install the chip deflector. 5 NOTE: The depth of cut should be between 0.10 and 0.20 mm (0.004 and 0.008 inch). Lighter cuts will cause the bit to heat up and wear faster. Heavier cuts will cause poor brake disc surface finish. Machine the brake disc. 6 Remove the lathe and, if installed, the silencer belt. 7 Remove the hub adapter. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Disc Machining > Page 7009 4. Remove the metal shavings. 5. For vehicles with a 2-piece brake disc and hub assembly: 1 Remove the brake disc from the hub. 2 Remove metal shavings from the hub, the brake disc mounting surfaces and from the ABS sensors. 3 Apply anti-seize lubricant to the hub mounting surface to prevent corrosion. 4 Align the match marks and install the brake disc on the hub. 6. NOTE: It is not required to install new brake pads if friction material properties are within guidelines. Install the brake caliper and brake caliper anchor bracket. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Disc Machining > Page 7010 Brake Rotor/Disc: Service and Repair Disc Removal and Installation, Front Brake Disc Removal and Installation Front Brake Disc System Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Disc Machining > Page 7011 Front Brake Disc System 1. Remove the brake caliper anchor plate. 2. Remove the brake disc. 3. Inspect the brake disc and resurface or install a new brake disc as necessary. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Disc Machining > Page 7012 Brake Rotor/Disc: Service and Repair Disc Removal and Installation, Rear Brake Disc Removal and Installation Rear Brake Disc Components 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. With the vehicle in NEUTRAL. position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. NOTE: When removing the disc brake caliper in this procedure, it is not necessary to disconnect the rear wheel brake hose. Remove the brake caliper anchor plate bolts. ^ To install, tighten to 190 Nm (140 ft. lbs.). 3. CAUTION: Do not allow the brake caliper to hang by the flexible brake hose or damage to the hose can occur. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Disc Machining > Page 7013 Remove the anchor plate and caliper as an assembly and position aside. ^ Support the caliper with mechanic's wire. 4. NOTE: If the brake disc binds on the parking brake shoe, remove the adjustment hole access plug and contract the parking brake shoe. Remove the brake disc. 5. Inspect the brake disc and resurface or install a new brake disc as necessary. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Disc Machining > Page 7014 Brake Rotor/Disc: Service and Repair Shield Removal and Installation, Front Brake Disc Shield Removal and Installation Front Brake Disc System Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Disc Machining > Page 7015 Front Brake Disc System 1. Remove the brake disc. 2. Remove the brake disc shield screws. ^ To install, tighten to 12 Nm (9 ft. lbs.). 3. Remove the brake disc shield. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Technical Service Bulletins > Customer Interest for Brake Bleeding: > 05-26-21 > Dec > 05 > Brakes - Unintended Brake Assist Brake Bleeding: Customer Interest Brakes - Unintended Brake Assist TSB 05-26-21 12/31/05 UNINTENDED BRAKE ASSIST FORD: 2003-2006 Expedition LINCOLN: 2003-2006 Navigator ISSUE Some 2003-2006 Expedition/Navigator may exhibit excessive pedal travel and/or low pedal effort, due to the mechanical or electronic brake assist being activated. ACTION Review the brake assist characteristics and follow the Service Procedure if required. Brake Assist Characteristics: The booster gain will be increased during panic braking, which increases brake pressure and reduces pedal forces. The brakes will go to maximum pressure and the tires will chirp, sounding as if the tires are locking up (normal anti-lock brake control should be present). The pedal efforts will drop dramatically since the booster is providing maximum boost, which allows the pedal to travel with little effort; this is normal. It feels as if the pedal travels excessively, but the system is generating maximum brake pressure when this occurs; again, this is normal. When statically applying the brake pedal very hard, you may hear or feel (in the pedal) a slight click. This is the brake assist feature engaging inside the booster. The system will remain active as long as the brake pedal is depressed. NOTE MECHANICAL BRAKE ASSIST BOOSTERS ARE USED ON VEHICLES NOT EQUIPPED WITH RIDE STABILITY CONTROL. Vehicles equipped with Ride Stability Control receive an electronic active booster, which provides the brake assist feature by activating an electronic solenoid inside the booster. The active booster will provide similar pedal feedback when the feature is engaged, but the subtle clicks will not be present. SERVICE PROCEDURE To service, first advise the customer that the feature is there to help assist during panic braking. If the customer did not experience a panic braking situation, then the brake assist may have been unintended, on a mechanical brake assist system. Check for conditions that would lower the brake pedal height and activate the brake assist. 1. Check for air in the brake lines, repair any leaks and bleed the brake lines as necessary. Refer to the Workshop Manual, Section 206-00 General Procedures. 2. Inspect the brake linings for excessive wear, which can increase the pedal travel and engage the mechanical brake assist. Refer to the Workshop Manual, Section 206-00 Diagnosis and Testing. 3. Check the vacuum line between the booster and the manifold for obstructions or kinks. Repair as necessary. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2001 30 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > 05-26-21 > Dec > 05 > Brakes Unintended Brake Assist Brake Bleeding: All Technical Service Bulletins Brakes - Unintended Brake Assist TSB 05-26-21 12/31/05 UNINTENDED BRAKE ASSIST FORD: 2003-2006 Expedition LINCOLN: 2003-2006 Navigator ISSUE Some 2003-2006 Expedition/Navigator may exhibit excessive pedal travel and/or low pedal effort, due to the mechanical or electronic brake assist being activated. ACTION Review the brake assist characteristics and follow the Service Procedure if required. Brake Assist Characteristics: The booster gain will be increased during panic braking, which increases brake pressure and reduces pedal forces. The brakes will go to maximum pressure and the tires will chirp, sounding as if the tires are locking up (normal anti-lock brake control should be present). The pedal efforts will drop dramatically since the booster is providing maximum boost, which allows the pedal to travel with little effort; this is normal. It feels as if the pedal travels excessively, but the system is generating maximum brake pressure when this occurs; again, this is normal. When statically applying the brake pedal very hard, you may hear or feel (in the pedal) a slight click. This is the brake assist feature engaging inside the booster. The system will remain active as long as the brake pedal is depressed. NOTE MECHANICAL BRAKE ASSIST BOOSTERS ARE USED ON VEHICLES NOT EQUIPPED WITH RIDE STABILITY CONTROL. Vehicles equipped with Ride Stability Control receive an electronic active booster, which provides the brake assist feature by activating an electronic solenoid inside the booster. The active booster will provide similar pedal feedback when the feature is engaged, but the subtle clicks will not be present. SERVICE PROCEDURE To service, first advise the customer that the feature is there to help assist during panic braking. If the customer did not experience a panic braking situation, then the brake assist may have been unintended, on a mechanical brake assist system. Check for conditions that would lower the brake pedal height and activate the brake assist. 1. Check for air in the brake lines, repair any leaks and bleed the brake lines as necessary. Refer to the Workshop Manual, Section 206-00 General Procedures. 2. Inspect the brake linings for excessive wear, which can increase the pedal travel and engage the mechanical brake assist. Refer to the Workshop Manual, Section 206-00 Diagnosis and Testing. 3. Check the vacuum line between the booster and the manifold for obstructions or kinks. Repair as necessary. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2001 30 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 7030 Brake Bleeding: By Symptom Technical Service Bulletin # 05-26-21 Date: 051231 Brakes - Unintended Brake Assist TSB 05-26-21 12/31/05 UNINTENDED BRAKE ASSIST FORD: 2003-2006 Expedition LINCOLN: 2003-2006 Navigator ISSUE Some 2003-2006 Expedition/Navigator may exhibit excessive pedal travel and/or low pedal effort, due to the mechanical or electronic brake assist being activated. ACTION Review the brake assist characteristics and follow the Service Procedure if required. Brake Assist Characteristics: The booster gain will be increased during panic braking, which increases brake pressure and reduces pedal forces. The brakes will go to maximum pressure and the tires will chirp, sounding as if the tires are locking up (normal anti-lock brake control should be present). The pedal efforts will drop dramatically since the booster is providing maximum boost, which allows the pedal to travel with little effort; this is normal. It feels as if the pedal travels excessively, but the system is generating maximum brake pressure when this occurs; again, this is normal. When statically applying the brake pedal very hard, you may hear or feel (in the pedal) a slight click. This is the brake assist feature engaging inside the booster. The system will remain active as long as the brake pedal is depressed. NOTE MECHANICAL BRAKE ASSIST BOOSTERS ARE USED ON VEHICLES NOT EQUIPPED WITH RIDE STABILITY CONTROL. Vehicles equipped with Ride Stability Control receive an electronic active booster, which provides the brake assist feature by activating an electronic solenoid inside the booster. The active booster will provide similar pedal feedback when the feature is engaged, but the subtle clicks will not be present. SERVICE PROCEDURE To service, first advise the customer that the feature is there to help assist during panic braking. If the customer did not experience a panic braking situation, then the brake assist may have been unintended, on a mechanical brake assist system. Check for conditions that would lower the brake pedal height and activate the brake assist. 1. Check for air in the brake lines, repair any leaks and bleed the brake lines as necessary. Refer to the Workshop Manual, Section 206-00 General Procedures. 2. Inspect the brake linings for excessive wear, which can increase the pedal travel and engage the mechanical brake assist. Refer to the Workshop Manual, Section 206-00 Diagnosis and Testing. 3. Check the vacuum line between the booster and the manifold for obstructions or kinks. Repair as necessary. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2001 30 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 7031 Disclaimer Technical Service Bulletin # 05-26-21 Date: 051231 Brakes - Unintended Brake Assist TSB 05-26-21 12/31/05 UNINTENDED BRAKE ASSIST FORD: 2003-2006 Expedition LINCOLN: 2003-2006 Navigator ISSUE Some 2003-2006 Expedition/Navigator may exhibit excessive pedal travel and/or low pedal effort, due to the mechanical or electronic brake assist being activated. ACTION Review the brake assist characteristics and follow the Service Procedure if required. Brake Assist Characteristics: The booster gain will be increased during panic braking, which increases brake pressure and reduces pedal forces. The brakes will go to maximum pressure and the tires will chirp, sounding as if the tires are locking up (normal anti-lock brake control should be present). The pedal efforts will drop dramatically since the booster is providing maximum boost, which allows the pedal to travel with little effort; this is normal. It feels as if the pedal travels excessively, but the system is generating maximum brake pressure when this occurs; again, this is normal. When statically applying the brake pedal very hard, you may hear or feel (in the pedal) a slight click. This is the brake assist feature engaging inside the booster. The system will remain active as long as the brake pedal is depressed. NOTE MECHANICAL BRAKE ASSIST BOOSTERS ARE USED ON VEHICLES NOT EQUIPPED WITH RIDE STABILITY CONTROL. Vehicles equipped with Ride Stability Control receive an electronic active booster, which provides the brake assist feature by activating an electronic solenoid inside the booster. The active booster will provide similar pedal feedback when the feature is engaged, but the subtle clicks will not be present. SERVICE PROCEDURE To service, first advise the customer that the feature is there to help assist during panic braking. If the customer did not experience a panic braking situation, then the brake assist may have been unintended, on a mechanical brake assist system. Check for conditions that would lower the brake pedal height and activate the brake assist. 1. Check for air in the brake lines, repair any leaks and bleed the brake lines as necessary. Refer to the Workshop Manual, Section 206-00 General Procedures. 2. Inspect the brake linings for excessive wear, which can increase the pedal travel and engage the mechanical brake assist. Refer to the Workshop Manual, Section 206-00 Diagnosis and Testing. 3. Check the vacuum line between the booster and the manifold for obstructions or kinks. Repair as necessary. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2001 30 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > Page 7032 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) Brake Bleeding: Service and Repair Four Wheel Anti-Lock Brake System (4WABS) Four Wheel Anti-Lock Brake System (4WABS) WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse 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 diagnostic 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 bleeding removes 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 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. ^ Tighten to 16 Nm (12 ft. lbs.). 5. Repeat Steps 1 through 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. ^ Tighten to 16 Nm (12 ft. lbs.). 6. NOTE: Go to the Help menu in the diagnostic tool. Connect the diagnostic tool DCL cable adapter into the vehicle data link connector (DLC) under the dash and follow the diagnostic tool instructions. 7. Repeat the conventional bleed procedure as outlined in Steps 1 through 5. 8. If the brake pedal feels spongy, repeat the diagnostic tool service bleed procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 7035 Brake Bleeding: Service and Repair Gravity Gravity WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse 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: 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 brake fluid. 2. Bleed the rear disc brake calipers. ^ 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. ^ 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. ^ Tighten to 16 Nm (12 ft. lbs.). 4. Bleed the front disc brake calipers. ^ 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 clean brake fluid. ^ 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. ^ Tighten to 16 Nm (12 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 7036 Brake Bleeding: Service and Repair Manual Manual WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse 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. ^ Tighten to 16 Nm (12 ft. lbs.). 5. Repeat Steps 1 through 4 for the LH rear disc brake caliper. 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 clean 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. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 7037 9. Tighten the RH front disc brake caliper bleeder screw. ^ Tighten to 16 Nm (12 ft. lbs.). 10. Repeat Steps 6 through 9 for the LH front disc brake caliper bleeder screw. 11. If necessary, bleed the brake master cylinder. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 7038 Brake Bleeding: Service and Repair Pressure Pressure WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. ^ WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse 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 operation. 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. 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. ^ Tighten to 16 Nm (12 ft. lbs.). 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. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 7039 8. Fill the brake master cylinder reservoir and install the brake master cylinder filler cap. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 7040 Brake Bleeding: Service and Repair Four Wheel Anti-Lock Brake System (4WABS) Four Wheel Anti-Lock Brake System (4WABS) WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse 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 diagnostic 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 bleeding removes 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 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. ^ Tighten to 16 Nm (12 ft. lbs.). 5. Repeat Steps 1 through 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. ^ Tighten to 16 Nm (12 ft. lbs.). 6. NOTE: Go to the Help menu in the diagnostic tool. Connect the diagnostic tool DCL cable adapter into the vehicle data link connector (DLC) under the dash and follow the diagnostic tool instructions. 7. Repeat the conventional bleed procedure as outlined in Steps 1 through 5. 8. If the brake pedal feels spongy, repeat the diagnostic tool service bleed procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 7041 Gravity Gravity WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse 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: 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 brake fluid. 2. Bleed the rear disc brake calipers. ^ 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. ^ 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. ^ Tighten to 16 Nm (12 ft. lbs.). 4. Bleed the front disc brake calipers. ^ 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 clean brake fluid. ^ 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. ^ Tighten to 16 Nm (12 ft. lbs.). Manual Manual WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 7042 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. ^ Tighten to 16 Nm (12 ft. lbs.). 5. Repeat Steps 1 through 4 for the LH rear disc brake caliper. 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 clean 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. ^ Tighten to 16 Nm (12 ft. lbs.). 10. Repeat Steps 6 through 9 for the LH front disc brake caliper bleeder screw. 11. If necessary, bleed the brake master cylinder. Pressure Pressure WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. ^ WARNING: 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. Failure to follow these instructions may result in personal injury. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 7043 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 operation. 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. 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. ^ Tighten to 16 Nm (12 ft. lbs.). 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. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 7044 8. Fill the brake master cylinder reservoir and install the brake master cylinder filler cap. Brake System Bleeding Brake System Bleeding Special Tool(s) Material WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse 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. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 7045 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 brake fluid. 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. 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. ^ Tighten to 25 Nm (18 ft. lbs.). Master Cylinder, Bench Master Cylinder, Bench WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse 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. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 7046 1. Support the brake master cylinder body in a vise and fill the brake master cylinder reservoir with specified brake fluid. ^ Use clean brake fluid. 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. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 06-12-5 > Jun > 06 > Brakes Roughness or Shudder When Braking Brake Caliper: Customer Interest Brakes - Roughness or Shudder When Braking TSB 06-12-5 06/26/06 BRAKE SHUDDER FORD: 2004-2006 Expedition LINCOLN: 2004-2006 Navigator This article supersedes TSB 06-3-17 to add a production fix date. ISSUE Some 2004-2006 Expedition/Navigator vehicles built between 12/18/2003 and 03/01/2006 may experience repeat front brake roughness and / or shudder while braking. ACTION Determine if the vehicle has the old level rotors. If old level rotors, replace the front rotors and front caliper assemblies. If vehicle has new level rotors replace caliper assemblies and turn or replace the rotors as appropriate. SERVICE PROCEDURE 1. Check the build date of the front rotors. The build date is stamped on the inside of the rotor, between the fins (Figure 1). If the rotor date code is before 4H23 (4=2004, H=August, 23=23rd), replace the front rotors and front caliper assemblies. Refer to Workshop Manual, Section 206-03 for front rotor and caliper replacement procedure. NOTE REPLACE CALIPERS WITH NEW SERVICE FIX CALIPER ASSEMBLIES BY REMOVING THE CALIPERS AT THE KNUCKLES. THE SERVICE REPLACEMENT CALIPERS WILL BE PRE-ASSEMBLED WITH ANCHOR, SPRINGS, AND PADS. THE CALIPERS SHOULD BE INSTALLED AS A UNIT WITHOUT DISASSEMBLY. 2. If the rotor date code is 4H23 or greater replace the caliper assemblies and use the on-the-car brake lathe to turn the rotor if still within minimum thickness specification. If rotor is beyond machinable thickness, replace the front rotors. NOTE DUE TO THE PISTON SEAL ROLLBACK DESIGN CHANGE WITHIN THE CALIPER, THE PEDAL TRAVEL MAY INCREASE APPROXIMATELY 9/32" (7 MM). THIS INCREASE IN TRAVEL IS CONSIDERED NORMAL. THIS CHANGE DOES NOT AFFECT BRAKE STOPPING DISTANCE AND/OR BRAKE EFFECTIVENESS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 06-12-5 > Jun > 06 > Brakes Roughness or Shudder When Braking > Page 7055 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061205A 2004-2006 0.9 Hr. Expedition/Navigator: Replace Front Brake Calipers, Replace Rotors (Do Not Use With 2000A, 2001BFA, 2001B2P, 2001B2PT, 2001B5FT, 2001B8F, 2001B8FT) 061205B 2004-2006 1.5 Hrs. Expedition/Navigator: Replace Front Brake Calipers, Refinish Rotors (Do Not Use With 2000A, 2001BFA, 2001B2P, 2001BPT, 2001B5FT, 2001B8F, 2001B8FT) DEALER CODING CONDITION BASIC PART NO. CODE 2B120 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 06-12-5 > Jun > 06 > Brakes - Roughness or Shudder When Braking Brake Caliper: All Technical Service Bulletins Brakes - Roughness or Shudder When Braking TSB 06-12-5 06/26/06 BRAKE SHUDDER FORD: 2004-2006 Expedition LINCOLN: 2004-2006 Navigator This article supersedes TSB 06-3-17 to add a production fix date. ISSUE Some 2004-2006 Expedition/Navigator vehicles built between 12/18/2003 and 03/01/2006 may experience repeat front brake roughness and / or shudder while braking. ACTION Determine if the vehicle has the old level rotors. If old level rotors, replace the front rotors and front caliper assemblies. If vehicle has new level rotors replace caliper assemblies and turn or replace the rotors as appropriate. SERVICE PROCEDURE 1. Check the build date of the front rotors. The build date is stamped on the inside of the rotor, between the fins (Figure 1). If the rotor date code is before 4H23 (4=2004, H=August, 23=23rd), replace the front rotors and front caliper assemblies. Refer to Workshop Manual, Section 206-03 for front rotor and caliper replacement procedure. NOTE REPLACE CALIPERS WITH NEW SERVICE FIX CALIPER ASSEMBLIES BY REMOVING THE CALIPERS AT THE KNUCKLES. THE SERVICE REPLACEMENT CALIPERS WILL BE PRE-ASSEMBLED WITH ANCHOR, SPRINGS, AND PADS. THE CALIPERS SHOULD BE INSTALLED AS A UNIT WITHOUT DISASSEMBLY. 2. If the rotor date code is 4H23 or greater replace the caliper assemblies and use the on-the-car brake lathe to turn the rotor if still within minimum thickness specification. If rotor is beyond machinable thickness, replace the front rotors. NOTE DUE TO THE PISTON SEAL ROLLBACK DESIGN CHANGE WITHIN THE CALIPER, THE PEDAL TRAVEL MAY INCREASE APPROXIMATELY 9/32" (7 MM). THIS INCREASE IN TRAVEL IS CONSIDERED NORMAL. THIS CHANGE DOES NOT AFFECT BRAKE STOPPING DISTANCE AND/OR BRAKE EFFECTIVENESS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 06-12-5 > Jun > 06 > Brakes - Roughness or Shudder When Braking > Page 7061 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061205A 2004-2006 0.9 Hr. Expedition/Navigator: Replace Front Brake Calipers, Replace Rotors (Do Not Use With 2000A, 2001BFA, 2001B2P, 2001B2PT, 2001B5FT, 2001B8F, 2001B8FT) 061205B 2004-2006 1.5 Hrs. Expedition/Navigator: Replace Front Brake Calipers, Refinish Rotors (Do Not Use With 2000A, 2001BFA, 2001B2P, 2001BPT, 2001B5FT, 2001B8F, 2001B8FT) DEALER CODING CONDITION BASIC PART NO. CODE 2B120 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Page 7062 General Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front Brake Caliper: Service and Repair Caliper Removal and Installation, Front Brake Caliper Material Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 7065 Front Brake Disc System Front Brake Disc System Removal and Installation Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 7066 WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. 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. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the brake pads. 3. CAUTION: Install a new lining if it is worn to or past the specified thickness above the metal backing plate or rivets. Install new pads in complete axle sets. Inspect the pads for wear or contamination. 4. Disconnect the front brake hose. ^ Use new copper washers to connect the front brake hose. ^ To install, tighten to 35 Nm (26 ft. lbs.). 5. Remove the disc brake caliper bolts. ^ To install, tighten to 55 Nm (41 ft. lbs.). 6. Inspect the brake disc and resurface or install a new brake disc as necessary. 7. Inspect the disc brake caliper for leaks. ^ If leaks are found, the brake caliper must be disassembled. 8. Bleed the brake system. 9. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 7067 Brake Caliper: Service and Repair Caliper Removal and Installation, Rear Brake Caliper Material Rear Brake Disc Components Removal and Installation WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 7068 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. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. 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. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the brake hose flow bolt and disconnect the hose. ^ Remove and discard the copper washers. ^ To install, tighten to 35 Nm (26 ft. lbs.). 3. Remove the brake pads. 4. Inspect the disc brake caliper for leaks. ^ If leaks are found, disassembly is required. 5. Bleed the brake system. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 7069 Brake Caliper: Service and Repair Brake Caliper Anchor Plate, Rear Brake Caliper Anchor Plate Material Rear Brake Disc Components Removal and Installation WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 7070 brakes inoperative. Failure to follow these instructions may result in personal injury. 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. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. Check the brake fluid level in the brake master cylinder reservoir. ^ If required, remove the fluid until the brake master cylinder reservoir is half full. 2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 3. Using the large C-clamp, compress the pistons into the caliper housing. 4. CAUTION: Do not allow the caliper to hang from the brake hose or damage to the hose can occur. Remove the 2 brake caliper guide pin bolts and position the caliper aside. ^ Support the caliper using mechanic's wire. ^ To install, tighten to 35 Nm (26 ft. lbs.). 5. Remove the brake pads from the caliper anchor plate. 6. Remove the 2 brake caliper anchor plate bolts and the brake caliper anchor plate. ^ To install, tighten to 190 Nm (140 ft. lbs.). 7. To install, reverse the removal procedure. ^ Test the brakes for normal operation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 7071 Brake Caliper: Service and Repair Brake Caliper Anchor Plate, Front Brake Caliper Anchor Plate Removal Front Brake Disc System Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 7072 Front Brake Disc System WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. If necessary, using a suitable suction device, remove the brake fluid in the master cylinder reservoir until it is half filled. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. 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. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 3. CAUTION: Install new brake pads if the lining(s) are worn to or past the specified thickness above the metal backing plate or rivets. Install new pads in complete axle sets. Inspect the brake pads for wear or contamination. ^ Install new pads as necessary. 4. CAUTION: If the anchor housing spring is to be reused, do not force the anchor housing spring off the brake caliper or damage to the spring can occur. Do not install a damaged anchor housing spring. Remove the anchor housing spring. 5. NOTE: The LH side anchor housing spring must be installed with the 2-tabbed end in the upper brake caliper cavity. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 7073 For the LH brake caliper, release the lower portion of the anchor housing spring. ^ Apply force at the center of the anchor housing spring and pull outward at the bottom of the anchor housing spring to remove it from the lower brake caliper cavity. 6. Rotate the spring upward then remove it from the brake caliper. 7. NOTE: The RH anchor housing spring must be installed with the 2-tabbed end in the lower brake caliper cavity. The illustration below shows the anchor housing spring end with 2 tabs. For RH brake caliper, release the upper portion of the anchor housing spring. ^ Apply force at the center of the anchor housing spring and pull outward at the top of the anchor housing spring to remove it from the upper brake caliper cavity. 8. Rotate the spring downward then remove it from the brake caliper. 9. NOTE: Do not allow the brake caliper to hang from the brake hose or damage to the hose can occur. Remove the guide pins and position the caliper aside. ^ Remove the zero-drag spring. ^ Remove and discard the brake caliper-to-anchor plate guide pins and boots. 10. Remove the brake caliper anchor plate bolts. 11. Remove the brake caliper anchor plate. Installation 1. Install the brake caliper anchor plate and bolts. ^ Tighten to 200 Nm (148 ft. lbs.). 2. Using brake parts cleaner, clean the inner surfaces of the brake caliper where the brake pads attach. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 7074 3. Install new brake hardware as follows: ^ Install the guide pin bushings into the caliper bores. ^ Apply grease to the inside of the guide pin bushing. Do not apply grease to the guide pin threads. ^ Push the guide pins into the bushing. 4. Install the inboard brake pad into the brake caliper. 5. Remove the protective paper from the outboard brake pad and install it into the brake caliper. 6. Install the brake caliper on the brake disc. 7. Install the guide pins and install the dust caps. ^ Tighten to 55 Nm (41 ft. lbs.). ^ Install the guide pin boots. 8. Install the zero-drag spring. NOTE: If present, the 2-tabbed end of the anchor housing spring must be installed first. 9. Install the anchor housing spring. 1 Insert the tab of the anchor housing spring into the brake caliper cavity. 2 Twist the tab into the brake caliper cavity (LH side-upper brake caliper cavity/RH side-lower brake caliper cavity). 10. Rotate the anchor housing spring and position the upper portion onto the anchor plate. 11. Position the other anchor housing spring portion onto the brake caliper anchor plate. 12. Push down and inward until the upper and lower ends of the anchor housing spring are latched and seated in the brake caliper cavities. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 7075 13. NOTE: The latch MUST be positioned as shown. Verify that the anchor housing spring is correctly latched. 14. Apply the brake several times to verify correct brake operation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 7076 Brake Caliper: Service and Repair Caliper Removal and Installation, Front Brake Caliper Material Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 7077 Front Brake Disc System Front Brake Disc System Removal and Installation Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 7078 WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. 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. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the brake pads. 3. CAUTION: Install a new lining if it is worn to or past the specified thickness above the metal backing plate or rivets. Install new pads in complete axle sets. Inspect the pads for wear or contamination. 4. Disconnect the front brake hose. ^ Use new copper washers to connect the front brake hose. ^ To install, tighten to 35 Nm (26 ft. lbs.). 5. Remove the disc brake caliper bolts. ^ To install, tighten to 55 Nm (41 ft. lbs.). 6. Inspect the brake disc and resurface or install a new brake disc as necessary. 7. Inspect the disc brake caliper for leaks. ^ If leaks are found, the brake caliper must be disassembled. 8. Bleed the brake system. 9. To install, reverse the removal procedure. Caliper Removal and Installation, Rear Brake Caliper Material Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 7079 Rear Brake Disc Components Removal and Installation WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. 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. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the brake hose flow bolt and disconnect the hose. ^ Remove and discard the copper washers. ^ To install, tighten to 35 Nm (26 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 7080 3. Remove the brake pads. 4. Inspect the disc brake caliper for leaks. ^ If leaks are found, disassembly is required. 5. Bleed the brake system. 6. To install, reverse the removal procedure. Brake Caliper Anchor Plate, Rear Brake Caliper Anchor Plate Material Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 7081 Rear Brake Disc Components Removal and Installation WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. Check the brake fluid level in the brake master cylinder reservoir. ^ If required, remove the fluid until the brake master cylinder reservoir is half full. 2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 3. Using the large C-clamp, compress the pistons into the caliper housing. 4. CAUTION: Do not allow the caliper to hang from the brake hose or damage to the hose can occur. Remove the 2 brake caliper guide pin bolts and position the caliper aside. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 7082 ^ Support the caliper using mechanic's wire. ^ To install, tighten to 35 Nm (26 ft. lbs.). 5. Remove the brake pads from the caliper anchor plate. 6. Remove the 2 brake caliper anchor plate bolts and the brake caliper anchor plate. ^ To install, tighten to 190 Nm (140 ft. lbs.). 7. To install, reverse the removal procedure. ^ Test the brakes for normal operation. Brake Caliper Anchor Plate, Front Brake Caliper Anchor Plate Removal Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 7083 Front Brake Disc System Front Brake Disc System WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. If necessary, using a suitable suction device, remove the brake fluid in the master cylinder reservoir until it is half filled. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. 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. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 3. CAUTION: Install new brake pads if the lining(s) are worn to or past the specified thickness above the metal backing plate or rivets. Install new pads in complete axle sets. Inspect the brake pads for wear or contamination. ^ Install new pads as necessary. 4. CAUTION: If the anchor housing spring is to be reused, do not force the anchor housing spring off the brake caliper or damage to the spring can occur. Do not install a damaged anchor housing spring. Remove the anchor housing spring. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 7084 5. NOTE: The LH side anchor housing spring must be installed with the 2-tabbed end in the upper brake caliper cavity. For the LH brake caliper, release the lower portion of the anchor housing spring. ^ Apply force at the center of the anchor housing spring and pull outward at the bottom of the anchor housing spring to remove it from the lower brake caliper cavity. 6. Rotate the spring upward then remove it from the brake caliper. 7. NOTE: The RH anchor housing spring must be installed with the 2-tabbed end in the lower brake caliper cavity. The illustration below shows the anchor housing spring end with 2 tabs. For RH brake caliper, release the upper portion of the anchor housing spring. ^ Apply force at the center of the anchor housing spring and pull outward at the top of the anchor housing spring to remove it from the upper brake caliper cavity. 8. Rotate the spring downward then remove it from the brake caliper. 9. NOTE: Do not allow the brake caliper to hang from the brake hose or damage to the hose can occur. Remove the guide pins and position the caliper aside. ^ Remove the zero-drag spring. ^ Remove and discard the brake caliper-to-anchor plate guide pins and boots. 10. Remove the brake caliper anchor plate bolts. 11. Remove the brake caliper anchor plate. Installation 1. Install the brake caliper anchor plate and bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 7085 ^ Tighten to 200 Nm (148 ft. lbs.). 2. Using brake parts cleaner, clean the inner surfaces of the brake caliper where the brake pads attach. 3. Install new brake hardware as follows: ^ Install the guide pin bushings into the caliper bores. ^ Apply grease to the inside of the guide pin bushing. Do not apply grease to the guide pin threads. ^ Push the guide pins into the bushing. 4. Install the inboard brake pad into the brake caliper. 5. Remove the protective paper from the outboard brake pad and install it into the brake caliper. 6. Install the brake caliper on the brake disc. 7. Install the guide pins and install the dust caps. ^ Tighten to 55 Nm (41 ft. lbs.). ^ Install the guide pin boots. 8. Install the zero-drag spring. NOTE: If present, the 2-tabbed end of the anchor housing spring must be installed first. 9. Install the anchor housing spring. 1 Insert the tab of the anchor housing spring into the brake caliper cavity. 2 Twist the tab into the brake caliper cavity (LH side-upper brake caliper cavity/RH side-lower brake caliper cavity). 10. Rotate the anchor housing spring and position the upper portion onto the anchor plate. 11. Position the other anchor housing spring portion onto the brake caliper anchor plate. 12. Push down and inward until the upper and lower ends of the anchor housing spring are latched and seated in the brake caliper cavities. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 7086 13. NOTE: The latch MUST be positioned as shown. Verify that the anchor housing spring is correctly latched. 14. Apply the brake several times to verify correct brake operation. Caliper Disassembly and Assembly, Front Brake Caliper Material Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 7087 Front Brake Disc System Front Brake Disc System Disassembly Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 7088 WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. Remove the brake caliper. 2. Apply low air pressure to the fluid port in the brake caliper. 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 brake caliper to force out the caliper pistons. 3 Remove the block of wood and the caliper pistons. 3. Remove the caliper piston seals and boots. 4. Inspect the caliper bores for scoring or corrosion. If scoring and corrosion exist, install a new brake caliper assembly. Assembly 1. Lubricate the caliper piston boots, caliper pistons, caliper piston seals and caliper bores with DOT 3 brake fluid. 2. Install the caliper pistons into the caliper bores. 1 Install the piston seals onto the caliper pistons. 2 Install the caliper piston boots onto the caliper pistons. 3 Insert the caliper pistons into the caliper bores. 4 Press the caliper pistons into the caliper bores. 3. Install the brake caliper. Caliper Disassembly and Assembly, Rear Brake Caliper Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 7089 Special Tool(s) Material Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 7090 Rear Brake Disc Components Disassembly WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. 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 piston. ^ Place a block of wood between the caliper bridge and the caliper piston. ^ Apply low air pressure to the fluid port in the disc brake caliper. ^ Force out the caliper piston to the block of wood. ^ Remove the block of wood and the caliper piston. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 7091 5. NOTE: Do not hone the cylinder bore. Caliper pistons are not available for honed cylinder bores. If the disc brake caliper cylinder bore or piston is excessively scored or corroded, install a new disc brake caliper. Remove and discard the piston seal and dust boot. Assembly CAUTION: Never reuse the piston seal or dust boot. 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. 1. Lubricate these items with brake fluid: ^ Cylinder bore. ^ Piston seal. ^ Caliper piston. ^ Dust boot. 2. Install the piston seal. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal and Installation, Front > Page 7092 3. Using the special tools, install the dust boot. 4. CAUTION: Be careful not to damage or dislodge the piston seal. CAUTION: Insert the caliper piston squarely into the caliper bore. Install the caliper piston. ^ Place the brake caliper in a vise. ^ Place the piston squarely against the dust boot. ^ While applying shop air into the brake caliper, push the piston squarely into the brake caliper bore. 5. Install the disc brake caliper. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid Ford P/N .............................................................................................................................................. ..................................................................... PM-1 Ford Specification ................................................ ..................................................................................................................................... ESA-M6C25-A Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 7099 C124 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 7100 Brake Fluid Level Sensor/Switch: Description and Operation Hydraulic Brake Actuation The brake pedal is connected to the power brake booster, which is connected to the brake master cylinder. The brake pedal is either fixed or adjustable; 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 front disc brake calipers and the rear disc brake calipers. The front disc brake caliper pistons are forced outward against the brake pads and contact the braking surface of the brake discs. 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. When the brake pedal is released, the pressure is relieved, returning the brake caliper pistons and the brake pads to the released 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. Brake Master Cylinder The brake master cylinder is a dual-piston type. The brake master cylinder is assisted by a power brake booster. These 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. Brake Fluid Level Warning Switch 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. Tubes and Hoses CAUTION: Only authorized inlet hydraulic brake tubes should be used. These tubes are of a specific design and new authorized parts only should be installed. Steel tubing with flex hoses are used in the hydraulic tubes between the brake master cylinder and the hydraulic control unit (HCU). Steel tubing is used between the HCU and the front and rear hoses. Double flared brake tubing provides 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Description and Operation Brake Hose/Line: Description and Operation Hydraulic Brake Actuation The brake pedal is connected to the power brake booster, which is connected to the brake master cylinder. The brake pedal is either fixed or adjustable; 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 front disc brake calipers and the rear disc brake calipers. The front disc brake caliper pistons are forced outward against the brake pads and contact the braking surface of the brake discs. 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. When the brake pedal is released, the pressure is relieved, returning the brake caliper pistons and the brake pads to the released 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. Brake Master Cylinder The brake master cylinder is a dual-piston type. The brake master cylinder is assisted by a power brake booster. These 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. Brake Fluid Level Warning Switch 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. Tubes and Hoses CAUTION: Only authorized inlet hydraulic brake tubes should be used. These tubes are of a specific design and new authorized parts only should be installed. Steel tubing with flex hoses are used in the hydraulic tubes between the brake master cylinder and the hydraulic control unit (HCU). Steel tubing is used between the HCU and the front and rear hoses. Double flared brake tubing provides 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control Unit (HCU) Material Removal and Installation WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable. For additional information, refer to Battery. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 7107 2. Disconnect the anti-lock brake system (ABS) module electrical connector. 3. CAUTION: Only authorized inlet hydraulic brake tubes should be used. These tubes are of specific design and only authorized parts should be used when installing new inlet brake tubes. NOTE: Plug each open port to prevent brake fluid from spilling. Disconnect the 6 brake tube fittings. ^ To install, tighten to 18 Nm (13 ft. lbs.). 4. Remove the 3 hydraulic control unit (HCU)-to-bracket bolts and the HCU. ^ To install, tighten to 9 Nm (80 inch lbs.). 5. To install, reverse the removal procedure. ^ Bleed the brake system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation Brake Master Cylinder: Description and Operation Hydraulic Brake Actuation The brake pedal is connected to the power brake booster, which is connected to the brake master cylinder. The brake pedal is either fixed or adjustable; 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 front disc brake calipers and the rear disc brake calipers. The front disc brake caliper pistons are forced outward against the brake pads and contact the braking surface of the brake discs. 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. When the brake pedal is released, the pressure is relieved, returning the brake caliper pistons and the brake pads to the released 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. Brake Master Cylinder The brake master cylinder is a dual-piston type. The brake master cylinder is assisted by a power brake booster. These 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. Brake Fluid Level Warning Switch 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. Tubes and Hoses CAUTION: Only authorized inlet hydraulic brake tubes should be used. These tubes are of a specific design and new authorized parts only should be installed. Steel tubing with flex hoses are used in the hydraulic tubes between the brake master cylinder and the hydraulic control unit (HCU). Steel tubing is used between the HCU and the front and rear hoses. Double flared brake tubing provides 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Brake Master Cylinder - Bypass Condition Test Brake Master Cylinder: Testing and Inspection Brake Master Cylinder - Bypass Condition Test Brake Master Cylinder - 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 installed new. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Brake Master Cylinder - Bypass Condition Test > Page 7113 Brake Master Cylinder: Testing and Inspection Compensator Port Check 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Page 7114 Brake Master Cylinder: Service and Repair Brake Master Cylinder Material Removal and Installation WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: 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. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. All vehicles 1. Disconnect the battery ground cable. For additional information, refer to Battery. Vehicles with cruise control 2. Disconnect the brake pressure switch electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Page 7115 All vehicles 3. Disconnect the brake fluid level switch. 4. Loosen the brake pipe fittings and disconnect the brake pipes. ^ Plug the master cylinder ports. ^ To install, tighten to 18 Nm (13 ft. lbs.). 5. Remove the 2 brake master cylinder nuts and the brake master cylinder. ^ To install, tighten to 22 Nm (16 ft. lbs.). 6. To install, reverse the removal procedure. ^ Bleed the brake system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Parking Brake Cable - Front Parking Brake Cable: Service and Repair Parking Brake Cable - Front Parking Brake Cable - Front Removal and Installation 1. Remove the parking brake control. 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 near the jack storage area in the rear of the passenger compartment. 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. If equipped, turn the air suspension switch to the OFF position. 3. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Parking Brake Cable - Front > Page 7121 4. Remove the front park brake cable P-clip-to-frame bolt. ^ To install, tighten to 15 Nm (11 ft. lbs.). 5. Remove the front parking brake cable and conduit. ^ Pry the rubber seal from the front floor pan. ^ Compress the retainer and release the conduit from the bracket. ^ Remove the front cable and conduit from the cable union. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Parking Brake Cable - Front > Page 7122 Parking Brake Cable: Service and Repair Parking Brake Cable - Rear Parking Brake Cable - RH Rear Removal and Installation 1. NOTE: Verify that the parking brake control is fully released. NOTE: This step will require the aid of an assistant. Relieve the tension on the parking brake cable system. ^ Pull down on the front parking brake cable at the connector clip. ^ Insert a 4 mm (5/32 inch) pin into the parking brake lever lockout hole. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Parking Brake Cable - Front > Page 7123 vehicle. This can be accomplished by turning off the air suspension switch located in the LH rear quarter trim panel. 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. Failure to follow these instructions may result in personal injury. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 3. Disconnect the RH rear cable. ^ Remove the RH rear cable from the cable union. ^ Compress the cable clip and release the conduit from the equalizer. 4. Remove the RH rear cable from the retaining clip. 5. Remove the bolt and the wireform bracket from the upper control arm. ^ To install, tighten to 35 Nm (26 ft. lbs.). 6. Remove the rear park brake cable P-clip-to-frame bolt from the crossmember. ^ To install, tighten to 9 Nm (80 inch lbs.). 7. Compress the retainer and release the conduit, then unclip the cable end fitting from the brake caliper lever. 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Parking Brake Cable - Front > Page 7124 Parking Brake Cable: Service and Repair Parking Brake Cable - LH Rear Parking Brake Cable - LH Rear Removal and Installation 1. NOTE: Verify that the parking brake control is fully released. NOTE: This step will require the aid of an assistant. Relieve the tension on the parking brake cable system. ^ Pull down on the front parking brake cable at the connector clip. ^ Insert a 4 mm (5/32 inch) pin into the parking brake lever lockout hole. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Parking Brake Cable - Front > Page 7125 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 LH rear quarter trim panel. 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. Failure to follow these instructions may result in personal injury. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 3. Separate the LH rear cable from the equalizer. 4. Remove the conduit from the bracket. 1 Compress the retainer. 2 Remove the conduit from the bracket. 5. NOTE: Be sure to correctly install the park brake cable retainer spring during installation or the park brake system will not operate correctly. Remove the LH rear cable. 1 Remove the LH rear cable from the retaining clip. 2 Disconnect the park brake cable retainer spring. 3 Disconnect the ABS sensor wire from the retaining clip. 6. Remove the wireform bracket retaining screw and the bracket. ^ To install, tighten to 35 Nm (26 ft. lbs.). 7. Compress the retainer and release the conduit, then unclip the cable end fitting from the brake caliper lever. 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Service and Repair Parking Brake Control: Service and Repair Parking Brake Control Removal and Installation 1. NOTE: Verify that the parking brake control is fully released. NOTE: This step will require the aid of an assistant. Relieve tension on the parking brake cable system. ^ Pull down on the front parking brake cable at the connector clip. ^ Insert a 4 mm (5/32 inch) pin into the parking brake lever lockout hole. 2. Remove the door scuff plate. 3. Remove the 2 screws and the instrument panel steering column cover. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Service and Repair > Page 7129 ^ Pull the weatherstrip back to release the edge of the panel. 4. Remove the parking brake release handle bolts. 5. Remove the retainer and the cowl trim panel. 6. Disconnect the parking brake release solenoid electrical connector. 7. Disconnect the parking brake switch electrical connector. 8. Remove the 3 parking brake control-to-cowl panel bolts. ^ To install, tighten to 20 Nm (15 ft. lbs.). 9. Straighten the tab on the take-up spool. 10. Disconnect the park brake cable conduit end fitting and remove the park brake control. ^ Compress the park brake cable conduit end fitting retainer to disconnect it from the control. 11. Remove the release handle and cable assembly from the controller. 12. Remove the release solenoid. ^ Pry the mounting bracket apart slightly to release the solenoid. 13. Remove the parking brake control. 14. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Motor > Component Information > Locations View 151-10 (behind Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Motor > Component Information > Locations > Page 7133 C2132 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch > Component Information > Service and Repair Parking Brake Release Switch: Service and Repair Parking Brake Release Switch NOTE: Floor shift shown, column shift similar. Removal and Installation Column shift (Expedition only) 1. NOTE: The parking brake release switch is located on the steering column. It is serviced as an assembly with the brake shift interlock. Remove the brake shift interlock/park brake release switch assembly. Floor shift 2. Remove the floor shift selector lever. 3. Disconnect the parking brake release switch electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch > Component Information > Service and Repair > Page 7137 4. Remove the 2 parking brake release switch screws and remove the switch. All vehicles 5. To install, reverse the removal procedure. ^ Make sure the switch is correctly aligned with the extension on the shifter before installing the screws. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair Parking Brake Shoe: Service and Repair Parking Brake Shoes Special Tool(s) Material Removal Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 7141 1. NOTE: Verify that the parking brake control is fully released. NOTE: This step will require the aid of an assistant. Relieve the tension on the parking brake cable system. ^ Pull down on the front parking brake cable at the coupler. ^ Insert a 4 mm (5/32 inch) pin into the parking brake lever. 2. Remove the brake disc. 3. Remove the front parking brake shoe retaining clip and pin. 4. Remove the parking brake shoe adjuster. ^ Using a suitable tool, spread the bottom of the parking brake shoes apart. ^ Remove the parking brake shoe adjuster. 5. Remove the parking brake shoe adjuster spring. 6. Slide the front parking brake shoe up and out of the guide flange. 7. Remove the front parking brake shoe. ^ Rotate the front parking brake shoe outward. ^ Remove the parking brake shoe return spring. 8. Remove the rear parking brake shoe. ^ Remove the retaining clip and pin. ^ Remove the rear parking brake shoe. 9. Inspect the components for excessive wear or damage and install new parts as required. Installation 1. NOTE: Before installation, lubricate the parking brake shoe contact points using silicone brake caliper grease. Install the rear parking brake shoe. ^ Hold the rear parking brake shoe in position. ^ Install the retaining pin and clip. 2. Install the front parking brake shoe. ^ Install the parking brake shoe return spring to the rear parking brake shoe and to the front parking brake shoe. ^ Rotate the front parking brake shoe into the guide flange. 3. Slide the front parking brake shoe down into position on the flange. 4. Install the front parking brake shoe retaining pin and clip. 5. Install the parking brake shoe adjuster spring. 6. Install the parking brake shoe adjuster. ^ Using a suitable tool, spread the bottom of the parking brake shoes apart. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 7142 ^ Install the parking brake shoe adjuster. 7. Using the special tool, measure the inside diameter of the drum portion of the rear brake disc. ^ Record the measurement. 8. NOTE: Make sure that the parking brake shoes are correctly centered. Take the measurement at the widest point across the center of the parking brake shoes. Using the special tool, measure the parking brake shoe diameter. ^ Rotate the adjuster to set the parking brake shoe diameter to 0.5 mm (0.02 inch) less than the recorded inside diameter of the drum portion of the rear brake disc. 9. Install the brake disc. 10. NOTE: This step will require the aid of an assistant. Enable the parking brake cable system. ^ Pull down on the front parking brake cable at the coupler. ^ Remove the retaining pin from the parking brake lever. 11. Check the operation of the parking brake. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations View 151-15 (LH A-Pillar) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 7146 C2015 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor > Component Information > Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor > Component Information > Locations > Page 7151 C149 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > Customer Interest for Vacuum Brake Booster: > 05-26-21 > Dec > 05 > Brakes Unintended Brake Assist Vacuum Brake Booster: Customer Interest Brakes - Unintended Brake Assist TSB 05-26-21 12/31/05 UNINTENDED BRAKE ASSIST FORD: 2003-2006 Expedition LINCOLN: 2003-2006 Navigator ISSUE Some 2003-2006 Expedition/Navigator may exhibit excessive pedal travel and/or low pedal effort, due to the mechanical or electronic brake assist being activated. ACTION Review the brake assist characteristics and follow the Service Procedure if required. Brake Assist Characteristics: The booster gain will be increased during panic braking, which increases brake pressure and reduces pedal forces. The brakes will go to maximum pressure and the tires will chirp, sounding as if the tires are locking up (normal anti-lock brake control should be present). The pedal efforts will drop dramatically since the booster is providing maximum boost, which allows the pedal to travel with little effort; this is normal. It feels as if the pedal travels excessively, but the system is generating maximum brake pressure when this occurs; again, this is normal. When statically applying the brake pedal very hard, you may hear or feel (in the pedal) a slight click. This is the brake assist feature engaging inside the booster. The system will remain active as long as the brake pedal is depressed. NOTE MECHANICAL BRAKE ASSIST BOOSTERS ARE USED ON VEHICLES NOT EQUIPPED WITH RIDE STABILITY CONTROL. Vehicles equipped with Ride Stability Control receive an electronic active booster, which provides the brake assist feature by activating an electronic solenoid inside the booster. The active booster will provide similar pedal feedback when the feature is engaged, but the subtle clicks will not be present. SERVICE PROCEDURE To service, first advise the customer that the feature is there to help assist during panic braking. If the customer did not experience a panic braking situation, then the brake assist may have been unintended, on a mechanical brake assist system. Check for conditions that would lower the brake pedal height and activate the brake assist. 1. Check for air in the brake lines, repair any leaks and bleed the brake lines as necessary. Refer to the Workshop Manual, Section 206-00 General Procedures. 2. Inspect the brake linings for excessive wear, which can increase the pedal travel and engage the mechanical brake assist. Refer to the Workshop Manual, Section 206-00 Diagnosis and Testing. 3. Check the vacuum line between the booster and the manifold for obstructions or kinks. Repair as necessary. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2001 30 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vacuum Brake Booster: > 05-26-21 > Dec > 05 > Brakes - Unintended Brake Assist Vacuum Brake Booster: All Technical Service Bulletins Brakes - Unintended Brake Assist TSB 05-26-21 12/31/05 UNINTENDED BRAKE ASSIST FORD: 2003-2006 Expedition LINCOLN: 2003-2006 Navigator ISSUE Some 2003-2006 Expedition/Navigator may exhibit excessive pedal travel and/or low pedal effort, due to the mechanical or electronic brake assist being activated. ACTION Review the brake assist characteristics and follow the Service Procedure if required. Brake Assist Characteristics: The booster gain will be increased during panic braking, which increases brake pressure and reduces pedal forces. The brakes will go to maximum pressure and the tires will chirp, sounding as if the tires are locking up (normal anti-lock brake control should be present). The pedal efforts will drop dramatically since the booster is providing maximum boost, which allows the pedal to travel with little effort; this is normal. It feels as if the pedal travels excessively, but the system is generating maximum brake pressure when this occurs; again, this is normal. When statically applying the brake pedal very hard, you may hear or feel (in the pedal) a slight click. This is the brake assist feature engaging inside the booster. The system will remain active as long as the brake pedal is depressed. NOTE MECHANICAL BRAKE ASSIST BOOSTERS ARE USED ON VEHICLES NOT EQUIPPED WITH RIDE STABILITY CONTROL. Vehicles equipped with Ride Stability Control receive an electronic active booster, which provides the brake assist feature by activating an electronic solenoid inside the booster. The active booster will provide similar pedal feedback when the feature is engaged, but the subtle clicks will not be present. SERVICE PROCEDURE To service, first advise the customer that the feature is there to help assist during panic braking. If the customer did not experience a panic braking situation, then the brake assist may have been unintended, on a mechanical brake assist system. Check for conditions that would lower the brake pedal height and activate the brake assist. 1. Check for air in the brake lines, repair any leaks and bleed the brake lines as necessary. Refer to the Workshop Manual, Section 206-00 General Procedures. 2. Inspect the brake linings for excessive wear, which can increase the pedal travel and engage the mechanical brake assist. Refer to the Workshop Manual, Section 206-00 Diagnosis and Testing. 3. Check the vacuum line between the booster and the manifold for obstructions or kinks. Repair as necessary. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2001 30 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > Page 7165 Vacuum Brake Booster: Description and Operation Brake Booster The power brake booster: ^ is a dual diaphragm, vacuum-assisted power brake booster. ^ reduces brake pedal pressure and travel distance. ^ is divided into separate vacuum and atmospheric pressure chambers by a diaphragm. If the power assist fails, the brake system will continue to operate with increased brake pedal effort. Hose and Check Valve The power brake booster check valve: ^ 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > Page 7166 Vacuum Brake Booster: Testing and Inspection Brake Booster 1. Check the hydraulic brake system for leaks or insufficient fluid. 2. With the transmission in NEUTRAL, stop the engine and apply the parking brake control. Apply the brake pedal several times to exhaust all vacuum in the system. 3. Apply the brake pedal and hold it in the applied position. Start the engine. If the vacuum system is operating, the brake pedal will tend to move downward under constant foot pressure. If no motion is felt, the power brake booster system is not functioning. Brake Booster Operation Check 1. Remove the vacuum booster hose from the check valve connection. Manifold vacuum must be available at the check valve end of the vacuum booster hose with the engine at idle speed and the transmission in NEUTRAL. If the manifold vacuum is available to the power brake booster, connect the vacuum booster hose to the power brake booster check valve and repeat Steps 2 and 3 of the Brake Booster check. If no downward movement of the brake pedal is felt, install a new power brake booster. 2. Operate the engine a minimum of 10 seconds at fast idle. Stop the engine, and let the vehicle stand for 10 minutes. Then apply the brake pedal with approximately 89 N (20 lb) of force. The brake pedal feel should be the same as that noted with the engine operating. If the brake pedal feels hard (no power assist), install a new power brake booster check valve and retest. If the brake pedal feels spongy, bleed the hydraulic system to remove air. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > Page 7167 Vacuum Brake Booster: Service and Repair Brake Booster Removal and Installation 1. Disconnect the battery ground cable. For additional information, refer to Battery. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > Page 7168 2. Loosen the clamp and separate the air cleaner outlet tube and resonator from the air cleaner. 3. Disconnect the mass air flow (MAF) sensor electrical connector. 4. Lift the air cleaner assembly from the air cleaner tray. 5. Remove the 3 power steering reservoir screws and position the reservoir aside. ^ To install, tighten to 11 Nm (8 ft. lbs.). 6. Disconnect the brake fluid level switch and if equipped, the brake pressure switch. 7. NOTE: Support the master cylinder with a wire tie or mechanic's wire. Remove and discard the 2 brake master cylinder nuts and position the master cylinder aside. ^ To install, tighten to 22 Nm (16 ft. lbs.). 8. Remove the 2 degas bottle bolts and position the degas bottle aside. ^ To install, tighten to 9 Nm (80 inch lbs.). 9. If equipped, disconnect the pedal travel sensor and solenoid electrical connectors. 10. Release the compression clamp and disconnect the vacuum brake booster hose. 11. Remove the cotter pin cover, pin, washer, bushing and switch, and disconnect the booster pushrod. 12. NOTE: The booster pushrod must be installed with the pushrod offset pointing downward. Remove the 4 brake booster-to-pedal bracket nuts and remove the vacuum brake booster. ^ To access the retaining nuts, fold back the sound insulation. ^ To install, tighten to 25 Nm (18 ft. lbs.). 13. To install, reverse the removal procedure. ^ Use new nuts when installing the master cylinder. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Testing and Inspection Vacuum Brake Booster Check Valve: Testing and Inspection Check Valve The function of the power brake booster check valve is to allow manifold vacuum to enter the power brake booster and prevent the escape of vacuum in case manifold vacuum is lost during sustained full throttle operation. To test the function of the power brake booster check valve: ^ Start and run the engine for at least 10 seconds. ^ Operate the brake pedal to check for power assist. ^ Disconnect the vacuum booster hose from the power brake booster. Do not remove the power brake booster check valve from the power brake booster. ^ There should be enough vacuum retained in the power brake booster for at least one more power-assisted brake operation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 7176 C135 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 7177 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System (ABS) Module Removal and Installation NOTE: When installing a new module, it must be calibrated and configured (either by download/upload or uploading the as-built data method). 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the anti-lock brake system (ABS) module electrical connector. 3. Remove the 3 bolts and the ABS module. ^ To install, tighten to 2 Nm (18 inch lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 7178 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Service and Repair ABS Sensor Block: Service and Repair Stability Control Sensor Cluster Removal and Installation NOTE: The lateral and longitudinal accelerometer and the roll rate sensor are located within the yaw rate sensor, stability control sensor cluster. 1. Remove the front floor console. For additional information, refer to Console. 2. Disconnect the stability control sensor cluster electrical connector. 3. Remove the 2 bolts and the stability control sensor cluster. ^ To install, tighten to 12 Nm (9 ft. lbs.). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations > Page 7186 C149 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 7190 C124 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 7191 Brake Fluid Level Sensor/Switch: Description and Operation Hydraulic Brake Actuation The brake pedal is connected to the power brake booster, which is connected to the brake master cylinder. The brake pedal is either fixed or adjustable; 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 front disc brake calipers and the rear disc brake calipers. The front disc brake caliper pistons are forced outward against the brake pads and contact the braking surface of the brake discs. 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. When the brake pedal is released, the pressure is relieved, returning the brake caliper pistons and the brake pads to the released 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. Brake Master Cylinder The brake master cylinder is a dual-piston type. The brake master cylinder is assisted by a power brake booster. These 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. Brake Fluid Level Warning Switch 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. Tubes and Hoses CAUTION: Only authorized inlet hydraulic brake tubes should be used. These tubes are of a specific design and new authorized parts only should be installed. Steel tubing with flex hoses are used in the hydraulic tubes between the brake master cylinder and the hydraulic control unit (HCU). Steel tubing is used between the HCU and the front and rear hoses. Double flared brake tubing provides 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Primary Brake Pressure Sensor View 151-1 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Primary Brake Pressure Sensor > Page 7196 View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Diagrams > Primary Brake Pressure Sensor C147 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Diagrams > Primary Brake Pressure Sensor > Page 7199 C148 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Service and Repair Lateral Accelerometer: Service and Repair Stability Control Sensor Cluster Removal and Installation NOTE: The lateral and longitudinal accelerometer and the roll rate sensor are located within the yaw rate sensor, stability control sensor cluster. 1. Remove the front floor console. For additional information, refer to Console. 2. Disconnect the stability control sensor cluster electrical connector. 3. Remove the 2 bolts and the stability control sensor cluster. ^ To install, tighten to 12 Nm (9 ft. lbs.). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Service and Repair Parking Brake Release Switch: Service and Repair Parking Brake Release Switch NOTE: Floor shift shown, column shift similar. Removal and Installation Column shift (Expedition only) 1. NOTE: The parking brake release switch is located on the steering column. It is serviced as an assembly with the brake shift interlock. Remove the brake shift interlock/park brake release switch assembly. Floor shift 2. Remove the floor shift selector lever. 3. Disconnect the parking brake release switch electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Service and Repair > Page 7206 4. Remove the 2 parking brake release switch screws and remove the switch. All vehicles 5. To install, reverse the removal procedure. ^ Make sure the switch is correctly aligned with the extension on the shifter before installing the screws. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations View 151-15 (LH A-Pillar) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 7210 C2015 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Service and Repair Steering Angle Sensor: Service and Repair Steering Wheel Rotation Sensor Removal and Installation 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the steering wheel rotation sensor electrical connector. 3. Remove the 2 bolts and the steering wheel rotation sensor. ^ To install, tighten to 4 Nm (35 inch lbs.). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations View 151-24 (Center Console) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 7217 C280 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Right Front View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Right Front > Page 7222 View 151-1 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Right Front > Page 7223 View 151-36 (Chassis, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 7226 C440 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 7227 C160 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 7228 C426 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Front Wheel Speed Sensor - Front Removal and Installation 1. NOTE: If equipped, turn the air suspension switch to the OFF position. With the vehicle in NEUTRAL, position it on a hoist 2. Disconnect the wheel speed sensor electrical connector. 3. Remove the wheel speed sensor harness retainer bolt and detach the retainers. ^ To install, tighten to 12 Nm (9 ft. lbs.). 4. CAUTION: Do not allow the caliper to hang from the brake hose or damage to the hose can result. Remove the 2 caliper anchor bolts and position the caliper, pads and anchor plate aside. ^ Support the caliper with mechanic's wire. ^ To install, tighten to 200 Nm (148 ft. lbs.). 5. Remove the brake disc. 6. Remove the front wheel speed sensor bolt and the sensor. ^ To install, tighten to 18 Nm (13 ft. lbs.). 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 7231 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Rear Wheel Speed Sensor - Rear Removal and Installation 1. Remove the parking brake shoes. 2. Disconnect the wheel speed sensor harness from the retaining clips. 3. Remove the rear wheel speed sensor bolt and the sensor. ^ To install, tighten to 18 Nm (13 ft. lbs.). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations View 151-12 (Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 7235 C245 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 7236 Yaw Rate Sensor: Service and Repair Stability Control Sensor Cluster Removal and Installation NOTE: The lateral and longitudinal accelerometer and the roll rate sensor are located within the yaw rate sensor, stability control sensor cluster. 1. Remove the front floor console. For additional information, refer to Console. 2. Disconnect the stability control sensor cluster electrical connector. 3. Remove the 2 bolts and the stability control sensor cluster. ^ To install, tighten to 12 Nm (9 ft. lbs.). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Locations View 151-14 (Steering Column) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions Ignition Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7244 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7245 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7246 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7247 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7248 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7249 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7250 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7251 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7252 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7253 Ignition Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7254 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7255 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7256 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7257 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7258 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7259 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7260 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7261 C250 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Page 7262 Ignition Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Page 7263 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Page 7264 Ignition Switch: Service and Repair Ignition Switch Ignition Switch Removal and Installation 1. Remove the steering wheel. 2. NOTE: Lower tilt release handle to access second screw. Remove the lower steering column shroud. ^ Remove the screws. 3. NOTE: The screw is located behind the multi-function switch. Remove the screw and the upper steering column shroud. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Page 7265 4. Remove the bolt, push the release and position the multi-function switch aside. 5. Disconnect the ignition switch electrical connector. 6. Remove the ignition switch. 7. To install, reverse the removal procedure. ^ Make sure that the spring located under the ignition switch is positioned on the steering column lock rod. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 7269 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 7270 C167 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 7275 View 151-1 (Engine Compartment) The fuel pump relay is located in the Central Junction Box (CJB), in the engine compartment, RH side. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 7276 C2163 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 7277 Starter Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 7278 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair Battery Cable: Service and Repair BATTERY CABLES Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Page 7283 Part 2 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery. 3. Remove the nut and position the ground cable terminal aside at the starter. - To install, tighten to 22 Nm (16 lb-ft). 4. Remove the nut and position the starter solenoid positive cable terminal aside. - To install, tighten to 12 Nm (9 lb-ft). 5. Remove the nut and position the starter solenoid wire terminal aside. - To install, tighten to 5 Nm (44 lb-in). 6. Disconnect the 2 battery cable harness locators from the A/C compressor mounting bolts. 7. Remove the bolt and position the battery ground cable-to-frame terminal aside. - To install, tighten to 30 Nm (22 lb-ft). 8. Remove the nut and position the generator harness terminal and the CJB cable terminal aside. - To install, tighten to 9 Nm (80 lb-in). 9. Remove the bolt and position the battery ground cable-to-cowl panel terminal aside. - To install, tighten to 12 Nm (9 lb-ft). 10. Disconnect the battery cable harness in-line electrical connector and remove the battery cable assembly. 11. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical Service Bulletins > Customer Interest for Alternator: > 06-19-12 > Oct > 06 > Charging System - DTC P0340/P0344/P0345/P0349 Alternator: Customer Interest Charging System - DTC P0340/P0344/P0345/P0349 TSB 06-19-12 10/02/06 DTC P0340/P0344/P0345/P0349-4.6L 3V AND 5.4L 3V FORD: 2005-2006 Mustang 2004-2005 F-150 2005-2006 Expedition, F-Super Duty 2006 Explorer 2007 Explorer Sport Trac LINCOLN: 2005-2006 Navigator MERCURY: 2006 Mountaineer This article supersedes TSB 06-2-9 to add a production fix date for Expedition and Navigator and service parts updated. ISSUE Some 2005-2006 F-Super Duty and Expedition/Navigator vehicles built prior to 12/14/2005 and 2004-2005 F-150 vehicles, equipped with 5.4L 3V engine, and 2005-2006 Mustang GT vehicles, equipped with 4.6L 3V engine, may exhibit a diagnostic trouble code (DTC) P0340 and/or P0344; or 2006 Explorer 4dr/Mountaineer and 2007 Explorer Sport Trac vehicles equipped with a 4.6L 3V engine may exhibit a DTC P0345 and/or P0349. This may be due to a malfunctioning diode or open phase connection in the generator. ACTION Perform a generator frequency test to diagnose cause of concern. Do not replace the generator unless a frequency test indicates a fault. This TSB provides step-by-step directions for performing a generator frequency test using the WDS oscilloscope function. SERVICE PROCEDURE NOTE USING THE OSCILLOSCOPE TO MEASURE PEAK-TO-PEAK VOLTAGE IS NOT A GOOD INDICATOR OF A FAULTY GENERATOR. NOTE ENSURE THERE IS NO BATTERY CHARGER CONNECTED TO THE VEHICLE. 1. Ensure the connections to the battery terminals, engine grounds, and generator B+ are clean and secure. 2. Attach WDS battery cable clamps to battery/battery cables. 3. Turn on WDS. 4. Select the Toolbox Icon, (upper left of WDS screen). 5. Select Oscilloscope and then click OK. 6. Select Channel 1, Auto, Generator Ripple. 7. Select Calculations, Channel 1, Frequency. 8. Select Calculations again. 9. Push the RUN/STOP button. A waveform should display on the screen. 10. Start the vehicle and leave at idle (engine speed less than 800 RPM). 11. Turn on vehicle loads (high beams, blower set on high, heated seats, defroster, etc). 12. Examine the frequency reading on WDS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical Service Bulletins > Customer Interest for Alternator: > 06-19-12 > Oct > 06 > Charging System - DTC P0340/P0344/P0345/P0349 > Page 7293 NOTE WDS CAN CALCULATE THE FREQUENCY AUTOMATICALLY. THE CALCULATED FREQUENCY IS LOCATED ON THE LOWER LEFT AREA OF THE OSCILLOSCOPE SCREEN. SOMETIMES THE FREQUENCY CANNOT BE CALCULATED BECAUSE THE WDS CANNOT RECOGNIZE AND MEASURE PEAK VALUES. IF THE WDS CANNOT CALCULATE THE FREQUENCY, IT WILL DISPLAY "INVALID" WHERE THE FREQUENCY READING SHOULD BE. THIS IS NORMAL IF THE RIPPLE VOLTAGE IS TOO LOW. 13. For a proper visible wave pattern, adjust the voltage scale and time scale until a good wave pattern is visible. Typically, a setting of 1mS/div and 100mV/div is a good starting point and can be adjusted as necessary. 14. Run vehicle until signal is steady. Then select the "RUN/STOP" button to freeze the waveform. 15. Determine if the generator is faulty based on frequency measurement: NOTE FREQUENCY IS DEPENDENT ON ENGINE RPM. PERFORM ALL TESTS AT IDLE OR FREQUENCY READINGS WILL BE INACCURATE. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical Service Bulletins > Customer Interest for Alternator: > 06-19-12 > Oct > 06 > Charging System - DTC P0340/P0344/P0345/P0349 > Page 7294 a. Compare the WDS saved waveform to the sample waveforms in Figure 1. If measured ripple frequency is lower than 500 Hz, then generator is faulty and should be replaced. If generator is not faulty proceed to Step 16. b. If frequency calculation cannot be made by WDS, it can be calculated manually. See MANUALLY CALCULATE FREQUENCY. If calculated ripple frequency is lower than 500 Hz, then generator is faulty and should be replaced. If generator is not faulty proceed to Step 16. MANUALLY CALCULATE FREQUENCY ^ Count the number of complete voltage dips over a given range of divisions on the scope trace Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical Service Bulletins > Customer Interest for Alternator: > 06-19-12 > Oct > 06 > Charging System - DTC P0340/P0344/P0345/P0349 > Page 7295 ^ Divide the number of voltage dips by the number of divisions to get the average voltage dips/division ^ Divide the value in Step 2 by the time scale (e.g. 1mS/div = .001 sec/division) to get frequency NOTE THIS METHOD OF CALCULATING FREQUENCY IS SLIGHTLY DIFFERENT THAN THE METHOD USED BY WDS, SO THE FREQUENCY MEASUREMENT VS. CALCULATED MAY BE SLIGHTLY DIFFERENT. 16. If the frequency test does not indicate a fault with the generator, proceed with normal Powertrain Controls/Emissions Diagnosis (PC/ED) diagnostics for the DTC. For F-Super Duty vehicles only, if the DTCs are still present after diagnostics, reprogram the powertrain control module (PCM) to the latest calibration using WDS release B38.11 and higher or B39.2 and higher. Calibration files may also be obtained at the website. This new calibration is not included in the B39 CD. (DO NOT REPROGRAM EXPEDITION/NAVIGATOR, F-150, MUSTANG, EXPLORER, MOUNTAINEER OR EXPLORER SPORT TRAC). Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061912A 2005-2006 0.8 Hr. Expedition/Navigator 5.4L 3V: Diagnose Generator Using WDS, If Generator Is Found Defective Replace Generator (Do Not Use With 10346A, 10200A) 061912B 2005-2006 Super Duty, 0.9 Hr. 2004-2005 F-150 5.4L 3V: Diagnose Generator Using WDS, If Generator Is Found Defective Replace Generator (Do Not Use With 10346A, 10200A) 061912C 2005-2006 Super Duty, 0.6 Hr. 5.4L 3V: Diagnose Generator Using WDS, If Generator Is Found To Be Functioning Properly Reprogram The Powertrain Control Module (Do Not Use With 10346A, 10200A, 12650D, 12650D84) 061912D 2005-2006 Mustang 4.6L 0.8 Hr. 3V: Diagnose Generator Using WDS, If Generator Is Found Defective Replace Generator (Do Not Use With 10346A 10200A, 9926A, 12650D, Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical Service Bulletins > Customer Interest for Alternator: > 06-19-12 > Oct > 06 > Charging System - DTC P0340/P0344/P0345/P0349 > Page 7296 1 2650D84) 061912E 2006 1.1 Hrs. Explorer/Mountaineer/2007 Explorer Sport Trac 4.6L 3V: Diagnose Generator Using WDS, If Generator Is Found Defective Replace Generator. (Do Not Use With 10346A 10200A, 9926A, 12650D, 1 2650D84) DEALER CODING CONDITION BASIC PART NO. CODE 10346 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alternator: > 06-19-12 > Oct > 06 > Charging System - DTC P0340/P0344/P0345/P0349 Alternator: All Technical Service Bulletins Charging System - DTC P0340/P0344/P0345/P0349 TSB 06-19-12 10/02/06 DTC P0340/P0344/P0345/P0349-4.6L 3V AND 5.4L 3V FORD: 2005-2006 Mustang 2004-2005 F-150 2005-2006 Expedition, F-Super Duty 2006 Explorer 2007 Explorer Sport Trac LINCOLN: 2005-2006 Navigator MERCURY: 2006 Mountaineer This article supersedes TSB 06-2-9 to add a production fix date for Expedition and Navigator and service parts updated. ISSUE Some 2005-2006 F-Super Duty and Expedition/Navigator vehicles built prior to 12/14/2005 and 2004-2005 F-150 vehicles, equipped with 5.4L 3V engine, and 2005-2006 Mustang GT vehicles, equipped with 4.6L 3V engine, may exhibit a diagnostic trouble code (DTC) P0340 and/or P0344; or 2006 Explorer 4dr/Mountaineer and 2007 Explorer Sport Trac vehicles equipped with a 4.6L 3V engine may exhibit a DTC P0345 and/or P0349. This may be due to a malfunctioning diode or open phase connection in the generator. ACTION Perform a generator frequency test to diagnose cause of concern. Do not replace the generator unless a frequency test indicates a fault. This TSB provides step-by-step directions for performing a generator frequency test using the WDS oscilloscope function. SERVICE PROCEDURE NOTE USING THE OSCILLOSCOPE TO MEASURE PEAK-TO-PEAK VOLTAGE IS NOT A GOOD INDICATOR OF A FAULTY GENERATOR. NOTE ENSURE THERE IS NO BATTERY CHARGER CONNECTED TO THE VEHICLE. 1. Ensure the connections to the battery terminals, engine grounds, and generator B+ are clean and secure. 2. Attach WDS battery cable clamps to battery/battery cables. 3. Turn on WDS. 4. Select the Toolbox Icon, (upper left of WDS screen). 5. Select Oscilloscope and then click OK. 6. Select Channel 1, Auto, Generator Ripple. 7. Select Calculations, Channel 1, Frequency. 8. Select Calculations again. 9. Push the RUN/STOP button. A waveform should display on the screen. 10. Start the vehicle and leave at idle (engine speed less than 800 RPM). 11. Turn on vehicle loads (high beams, blower set on high, heated seats, defroster, etc). 12. Examine the frequency reading on WDS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alternator: > 06-19-12 > Oct > 06 > Charging System - DTC P0340/P0344/P0345/P0349 > Page 7302 NOTE WDS CAN CALCULATE THE FREQUENCY AUTOMATICALLY. THE CALCULATED FREQUENCY IS LOCATED ON THE LOWER LEFT AREA OF THE OSCILLOSCOPE SCREEN. SOMETIMES THE FREQUENCY CANNOT BE CALCULATED BECAUSE THE WDS CANNOT RECOGNIZE AND MEASURE PEAK VALUES. IF THE WDS CANNOT CALCULATE THE FREQUENCY, IT WILL DISPLAY "INVALID" WHERE THE FREQUENCY READING SHOULD BE. THIS IS NORMAL IF THE RIPPLE VOLTAGE IS TOO LOW. 13. For a proper visible wave pattern, adjust the voltage scale and time scale until a good wave pattern is visible. Typically, a setting of 1mS/div and 100mV/div is a good starting point and can be adjusted as necessary. 14. Run vehicle until signal is steady. Then select the "RUN/STOP" button to freeze the waveform. 15. Determine if the generator is faulty based on frequency measurement: NOTE FREQUENCY IS DEPENDENT ON ENGINE RPM. PERFORM ALL TESTS AT IDLE OR FREQUENCY READINGS WILL BE INACCURATE. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alternator: > 06-19-12 > Oct > 06 > Charging System - DTC P0340/P0344/P0345/P0349 > Page 7303 a. Compare the WDS saved waveform to the sample waveforms in Figure 1. If measured ripple frequency is lower than 500 Hz, then generator is faulty and should be replaced. If generator is not faulty proceed to Step 16. b. If frequency calculation cannot be made by WDS, it can be calculated manually. See MANUALLY CALCULATE FREQUENCY. If calculated ripple frequency is lower than 500 Hz, then generator is faulty and should be replaced. If generator is not faulty proceed to Step 16. MANUALLY CALCULATE FREQUENCY ^ Count the number of complete voltage dips over a given range of divisions on the scope trace Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alternator: > 06-19-12 > Oct > 06 > Charging System - DTC P0340/P0344/P0345/P0349 > Page 7304 ^ Divide the number of voltage dips by the number of divisions to get the average voltage dips/division ^ Divide the value in Step 2 by the time scale (e.g. 1mS/div = .001 sec/division) to get frequency NOTE THIS METHOD OF CALCULATING FREQUENCY IS SLIGHTLY DIFFERENT THAN THE METHOD USED BY WDS, SO THE FREQUENCY MEASUREMENT VS. CALCULATED MAY BE SLIGHTLY DIFFERENT. 16. If the frequency test does not indicate a fault with the generator, proceed with normal Powertrain Controls/Emissions Diagnosis (PC/ED) diagnostics for the DTC. For F-Super Duty vehicles only, if the DTCs are still present after diagnostics, reprogram the powertrain control module (PCM) to the latest calibration using WDS release B38.11 and higher or B39.2 and higher. Calibration files may also be obtained at the website. This new calibration is not included in the B39 CD. (DO NOT REPROGRAM EXPEDITION/NAVIGATOR, F-150, MUSTANG, EXPLORER, MOUNTAINEER OR EXPLORER SPORT TRAC). Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061912A 2005-2006 0.8 Hr. Expedition/Navigator 5.4L 3V: Diagnose Generator Using WDS, If Generator Is Found Defective Replace Generator (Do Not Use With 10346A, 10200A) 061912B 2005-2006 Super Duty, 0.9 Hr. 2004-2005 F-150 5.4L 3V: Diagnose Generator Using WDS, If Generator Is Found Defective Replace Generator (Do Not Use With 10346A, 10200A) 061912C 2005-2006 Super Duty, 0.6 Hr. 5.4L 3V: Diagnose Generator Using WDS, If Generator Is Found To Be Functioning Properly Reprogram The Powertrain Control Module (Do Not Use With 10346A, 10200A, 12650D, 12650D84) 061912D 2005-2006 Mustang 4.6L 0.8 Hr. 3V: Diagnose Generator Using WDS, If Generator Is Found Defective Replace Generator (Do Not Use With 10346A 10200A, 9926A, 12650D, Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alternator: > 06-19-12 > Oct > 06 > Charging System - DTC P0340/P0344/P0345/P0349 > Page 7305 1 2650D84) 061912E 2006 1.1 Hrs. Explorer/Mountaineer/2007 Explorer Sport Trac 4.6L 3V: Diagnose Generator Using WDS, If Generator Is Found Defective Replace Generator. (Do Not Use With 10346A 10200A, 9926A, 12650D, 1 2650D84) DEALER CODING CONDITION BASIC PART NO. CODE 10346 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications Alternator: Electrical Specifications Item....................................................................................................................................................... ..............................................................Specification Voltage................................................................................................................................................. ........................................................................12 volts Generator amps...............................................................................65/110 amp (max) @ 1,800-6,000 generator rpm, approximately 500-2,000 engine rpm Generator Load at 2,000 rpm................................................................................................................................ ....................................................................65 amps No Load at 2,000 rpm........................................ .......................................................................................................................between 13.2 and 15.5 volts Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications > Page 7308 Torque Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions Alternator: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7311 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7312 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7313 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7314 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7315 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7316 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7317 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7318 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7319 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7320 Alternator: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7321 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7322 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7323 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7324 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7325 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7326 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7327 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 7328 Alternator: Connector Views C102a C102b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 7329 Alternator: Application and ID Item....................................................................................................................................................... ..............................................................Specification Generator Rating..............................................................................................65/110 amp (max) @ 1,800-6,000 generator rpm, approximately 500-2,000 engine rpm Generator pulley ratio................... .............................................................................................................................................................. ....................2.96:1 Voltage regulator type........................................................................................... ...............................................................Electronic internal with generator Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 7330 Alternator: Description and Operation GENERATOR The generator is belt-driven by the engine accessory drive system. The generator has an internal voltage regulator that is not replaced separately. A new generator and voltage regulator are repaired as an assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 7331 Alternator: Service and Repair GENERATOR Removal and Installation CAUTION: Do not allow any metal object to come in contact with the generator housing and internal diode cooling fins. A short circuit may result and burn out the diodes. 1. Disconnect the battery. 2. For Navigator, release the 2 retainers and remove the engine cover. 3. Remove the air cleaner intake pipe. 4. Rotate the front end accessory drive belt tensioner counterclockwise and position the accessory drive belt aside. 5. Remove the harness locator from the generator bracket. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 7332 6. Remove the 4 bolts and the generator bracket. - To install, tighten to 10 Nm (89 lb-in). 7. Remove the 2 bolts and position the generator aside. - Tighten to 25 Nm (18 lb-ft). 8. Disconnect the generator electrical connector. 9. Position the generator B+ protective cover aside, remove the nut and position the generator B+ terminal aside. - To install, tighten to 8 Nm (71 lb-in). 10. Remove the generator. 11. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Ignition Lock Cylinder - Non Functional Ignition Lock: Service and Repair Ignition Lock Cylinder - Non Functional IGNITION LOCK CYLINDER - NON FUNCTIONAL Removal and Installation 1. Remove the passive anti-theft system (PATS) transceiver. 2. Remove the ignition lock cylinder. - Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. - Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition lock cylinder breaks loose. - Remove and discard the ignition lock cylinder and drill shavings from the steering column. 3. Remove the bearing retainer. 4. Remove the steering column lock housing bearing and steering column lock gear. - Thoroughly clean all drill shavings from the steering column and inspect it for damage. 5. NOTE: Use a new ignition lock cylinder. To install, reverse the removal procedure. Verify ignition switch lock cylinder operation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Ignition Lock Cylinder - Non Functional > Page 7338 Ignition Lock: Service and Repair Ignition Lock Cylinder - Functional IGNITION LOCK CYLINDER - FUNCTIONAL Removal and Installation 1. Remove the passive anti-theft system (PATS) transceiver. 2. NOTE: The ignition lock cylinder must be in the accessory position. Remove the ignition lock cylinder. 1. Press the release pin. 2 Remove the lock cylinder. Verify the ignition switch lock operation. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Locations View 151-14 (Steering Column) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions Ignition Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7344 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7345 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7346 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7347 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7348 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7349 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7350 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7351 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7352 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7353 Ignition Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7354 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7355 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7356 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7357 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7358 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7359 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7360 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7361 C250 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Page 7362 Ignition Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Page 7363 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Page 7364 Ignition Switch: Service and Repair Ignition Switch Ignition Switch Removal and Installation 1. Remove the steering wheel. 2. NOTE: Lower tilt release handle to access second screw. Remove the lower steering column shroud. ^ Remove the screws. 3. NOTE: The screw is located behind the multi-function switch. Remove the screw and the upper steering column shroud. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Page 7365 4. Remove the bolt, push the release and position the multi-function switch aside. 5. Disconnect the ignition switch electrical connector. 6. Remove the ignition switch. 7. To install, reverse the removal procedure. ^ Make sure that the spring located under the ignition switch is positioned on the steering column lock rod. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 7369 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 7370 C167 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 (V8-5.4L VIN 5 (2006)) 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 7379 CONDITION BASIC PART NO. CODE 14A280 01 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 (V8-5.4L VIN 5 (2006)) 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 7385 CONDITION BASIC PART NO. CODE 14A280 01 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Starter Cable: > 05-22-17 > Nov > 05 > Restraints - Cannot Disable 'Belt Minder' Chime Seat Belt Control Module: All Technical Service Bulletins Restraints - Cannot Disable 'Belt Minder' Chime TSB 05-22-17 11/14/05 INABILITY TO DISABLE THE SUPPLEMENTAL SAFETY BELT WARNING CHIME (BELTMINDER) FORD: 2006 Expedition LINCOLN: 2006 Navigator ISSUE Some 2006 Expedition/Navigator vehicles may exhibit an inability to disable the Belt Minder function following procedures listed in the Workshop Manual or the Owner Guide. The Belt Minder function operates normally, but can not be turned off (if desired by the customer). ACTION Replace the restraint control module (RCM), which includes software to disable the Belt Minder. Refer to Workshop Manual, Section 501-20B to replace the RCM. Then follow Workshop Manual, Section 413-09 or the Owner Guide procedure to disable the Belt Minder function. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052217A 2006 Expedition: Replace 1.0 Hrs. The Restraints Control Module Includes Time To Depower And Repower The Supplemental Restraints System And Disable The Beltminder (Do Not Use With 14056D, 14056D1B, 14056D1C, 14056D1XN, 14056DZR) 052217A 2006 Navigator: Replace 1.2 Hrs. The Restraints Control Module Includes Time To Depower And Repower The Supplemental Restraints System And Disable The Beltminder (Do Not Use With 14056D, 14056D1B, 14056D1C, 14056D1XN, 14056DZR) DEALER CODING CONDITION BASIC PART NO. CODE 14B321 42 OASIS CODES: 104000, 206000 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Starter Cable: > 05-22-17 > Nov > 05 > Restraints - Cannot Disable 'Belt Minder' Chime > Page 7391 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Starter Cable: > 05-22-17 > Nov > 05 > Restraints - Cannot Disable 'Belt Minder' Chime > Page 7397 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > Customer Interest for Starter Motor: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition Starter Motor: Customer Interest Starting System- No Crank Condition TSB 06-19-14 10/02/06 NO CRANK / STARTER TERMINAL FATIGUE FORD: 1997-2007 Crown Victoria 1997-2004 F-150 Heritage 1997-2006 Expedition 1998-2006 E-Series 1999-2006 F-Super Duty 2002-2007 Explorer 2004-2006 F-150 2007 Explorer Sport Trac LINCOLN: 1998-2006 Navigator 2003-2005 Aviator MERCURY: 1997-2007 Grand Marquis 2002-2007 Mountaineer ISSUE Some vehicles may exhibit a no crank condition due to an open circuit in the starter relay to starter motor circuit at the starter motor connection. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE A new starter terminal wiring pigtail kit is released eliminating the need to replace the entire harness for the terminal connection. NOTE TERMINAL KIT ONLY SERVICES THE STARTER RELAY TO STARTER MOTOR CIRCUIT. THE KIT DOES NOT SERVICE STARTER MOTOR BATTERY POWER CIRCUIT. Refer to instruction sheet contained in Wiring Pigtail Kit for wiring harness service procedure. NOTE REFERENCE THE APPROPRIATE WORKSHOP MANUAL SERVICE SECTION 303-06 FOR REMOVAL AND INSTALLATION OF THE STARTER MOTOR WIRING TERMINAL CONNECTION PROCEDURES. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061914A Install Wiring Pigtail kit (Do 0.4 Hr. Not Use With 14200A) MT061914 Claim Additional Labor Actual Required As Actual Time Time Or Use SLTS Operation If Available DEALER CODING Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > Customer Interest for Starter Motor: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition > Page 7406 CONDITION BASIC PART NO. CODE 14A280 01 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Starter Motor: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition Starter Motor: All Technical Service Bulletins Starting System- No Crank Condition TSB 06-19-14 10/02/06 NO CRANK / STARTER TERMINAL FATIGUE FORD: 1997-2007 Crown Victoria 1997-2004 F-150 Heritage 1997-2006 Expedition 1998-2006 E-Series 1999-2006 F-Super Duty 2002-2007 Explorer 2004-2006 F-150 2007 Explorer Sport Trac LINCOLN: 1998-2006 Navigator 2003-2005 Aviator MERCURY: 1997-2007 Grand Marquis 2002-2007 Mountaineer ISSUE Some vehicles may exhibit a no crank condition due to an open circuit in the starter relay to starter motor circuit at the starter motor connection. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE A new starter terminal wiring pigtail kit is released eliminating the need to replace the entire harness for the terminal connection. NOTE TERMINAL KIT ONLY SERVICES THE STARTER RELAY TO STARTER MOTOR CIRCUIT. THE KIT DOES NOT SERVICE STARTER MOTOR BATTERY POWER CIRCUIT. Refer to instruction sheet contained in Wiring Pigtail Kit for wiring harness service procedure. NOTE REFERENCE THE APPROPRIATE WORKSHOP MANUAL SERVICE SECTION 303-06 FOR REMOVAL AND INSTALLATION OF THE STARTER MOTOR WIRING TERMINAL CONNECTION PROCEDURES. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061914A Install Wiring Pigtail kit (Do 0.4 Hr. Not Use With 14200A) MT061914 Claim Additional Labor Actual Required As Actual Time Time Or Use SLTS Operation If Available DEALER CODING Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Starter Motor: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition > Page 7412 CONDITION BASIC PART NO. CODE 14A280 01 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Electrical Specifications Starter Motor: Electrical Specifications Item....................................................................................................................................................... ..............................................................Specification Normal engine cranking speed............................................................................................................. ................................................................140-220 rpm Starter motor armature shaft maximum runout...........................................................................................................................................0.11 mm (0.004 in) Starter motor brush manufactured length...................................................................... ..............................................................................16.8 mm (0.66 in.) Starter motor brush spring tens ion......................................................................................................................................................... ...............18 N (65 oz) Starter motor commutator maximum runout..................................................... ..........................................................................................0.12 mm (0.005 in) Starter motor diameter .............................................................................................................................................................. ....................101.6 mm (4.0 in) Starter motor maximum load............................................................... ......................................................................................................................800 amps Starter motor minimum stall torque (at 5 volts)........................................................................................................................................14.7 Nm (10.8 lb-ft) Starter motor no load current draw............................................................................... ..........................................................................................60-80 amps Starter motor normal load current draw.......................................................................................................................................... ....................130-220 amps Starter circuit maximum voltage drop (engine at normal operating temperature).......................................................................................................0.5 volts Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Electrical Specifications > Page 7415 Torque Specificiations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 7416 View 151-1 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 7417 Starter Motor: Diagrams C197a C197b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 7418 Starter Motor: Service and Repair STARTER MOTOR Removal WARNING: When carrying out maintenance on the starting system, be aware that the heavy gauge leads are connected directly to the battery. Make sure the protective caps are in place when maintenance is completed. Failure to follow these instructions may result in personal injury. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the starter terminal cover and remove the nut and the solenoid S-terminal electrical connection. 4. Remove the nut and the solenoid B-terminal electrical connection. 5. Remove the nut and the starter battery ground cable from the stud. 6. Remove the 2 bolts, the stud bolt and the starter motor. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 7419 1. Position the starter and install the 2 bolts and the stud bolt in 3 stages. - Stage 1: Install the 2 starter bolts and the stud bolt finger tight. - Stage 2: Tighten the upper bolt to 25 Nm (18 lb-ft). - Stage 3: Tighten the lower bolt and stud bolt to 25 Nm (18 lb-ft). 2. Position the starter battery ground cable onto the stud and install the nut. - Tighten to 20 Nm (15 lb-ft). 3. Connect the solenoid B terminal electrical connection and install the nut. - Tighten to 12 Nm (9 lb-ft). 4. Connect the solenoid S terminal electrical connection and install the nut and the starter terminal cover. - Tighten to 6 Nm (53 lb-in). 5. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 7423 View 151-1 (Engine Compartment) The fuel pump relay is located in the Central Junction Box (CJB), in the engine compartment, RH side. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 7424 C2163 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 7425 Starter Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 7426 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear C474 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear > Page 7432 C2033 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear > Page 7433 C3063 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear > Page 7434 C3064 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear > Page 7435 C3243 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor 1 C174 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor 1 > Page 7440 C194 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Central Junction Box Fuse: Locations Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Central Junction Box > Page 7445 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Central Junction Box > Page 7446 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Central Junction Box > Page 7447 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Central Junction Box > Page 7448 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Central Junction Box > Page 7449 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Central Junction Box > Page 7450 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Central Junction Box > Page 7451 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Central Junction Box > Page 7452 Fuse: Locations Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Central Junction Box > Page 7453 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Central Junction Box > Page 7454 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Central Junction Box > Page 7455 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Central Junction Box > Page 7456 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Central Junction Box > Page 7457 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7460 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7461 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7462 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7463 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7464 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7465 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7466 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7467 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7468 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7469 Fuse: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7470 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7471 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7472 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7473 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7474 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7475 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7476 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central Junction Box Fuse: Application and ID Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central Junction Box > Page 7479 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central Junction Box > Page 7480 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central Junction Box > Page 7481 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central Junction Box > Page 7482 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central Junction Box > Page 7483 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central Junction Box > Page 7484 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central Junction Box > Page 7485 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central Junction Box > Page 7486 Fuse: Application and ID Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central Junction Box > Page 7487 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central Junction Box > Page 7488 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central Junction Box > Page 7489 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central Junction Box > Page 7490 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central Junction Box > Page 7491 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central Junction Box Fuse Block: Locations Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central Junction Box > Page 7496 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central Junction Box > Page 7497 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central Junction Box > Page 7498 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central Junction Box > Page 7499 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central Junction Box > Page 7500 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central Junction Box > Page 7501 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central Junction Box > Page 7502 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central Junction Box > Page 7503 Fuse Block: Locations Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central Junction Box > Page 7504 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central Junction Box > Page 7505 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central Junction Box > Page 7506 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central Junction Box > Page 7507 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central Junction Box > Page 7508 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7511 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7512 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7513 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7514 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7515 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7516 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7517 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7518 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7519 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7520 Fuse Block: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7521 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7522 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7523 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7524 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7525 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7526 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7527 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7528 Fuse Block: Connector Views C270a C270b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7529 C270c C270d Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7530 C270e Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7531 C270f C270g Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7532 C270h C270j Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7533 C270k C270m Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7534 C270n C270p Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Central Junction Box Fuse Block: Application and ID Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 7537 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 7538 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 7539 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 7540 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 7541 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 7542 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 7543 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 7544 Fuse Block: Application and ID Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 7545 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 7546 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 7547 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 7548 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 7549 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 7553 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 7557 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 Multiple Junction Connector: Diagrams C110-C314 C110 C133 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7562 C134 C144 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7563 C145 C146 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7564 C192 C210 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7565 C211 C212 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7566 C213 C214 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7567 C215 C219 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7568 C237 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7569 C238 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7570 C248 C260 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7571 C263 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7572 C265 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7573 C268 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7574 C291 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7575 C298 C299 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7576 C311 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7577 C312 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7578 C314 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7579 Multiple Junction Connector: Diagrams C315-C2108 C315 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7580 C316 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7581 C327 C328 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7582 C340 C405 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7583 C406 C410 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7584 C411 C421 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7585 C422 C465 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7586 C494 C495 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7587 C510 C610 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7588 C700 C800 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7589 C913 C922 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7590 C925 C934 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7591 C935 C991 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7592 C1010 C1026 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7593 C2108 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7597 C2110 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7598 Power Distribution Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7599 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 7604 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 7608 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7612 C2110 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7613 Power Distribution Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7614 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box Relay Box: Locations Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7619 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7620 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7621 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7622 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7623 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7624 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7625 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7626 Relay Box: Locations Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7627 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7628 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7629 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7630 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7631 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7632 Relay Box: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7633 C270a Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7634 C270b C270c Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7635 C270d Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7636 C270e Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7637 C270f C270g Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7638 C270h C270j Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7639 C270k C270m Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7640 C270n C270p Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box Relay Box: Application and ID Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7643 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7644 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7645 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7646 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7647 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7648 Relay Box: Application and ID Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7649 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7650 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7651 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7652 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7653 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7654 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7655 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box Relay Box: Locations Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7660 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7661 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7662 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7663 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7664 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7665 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7666 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7667 Relay Box: Locations Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7668 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7669 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7670 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7671 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7672 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7673 Relay Box: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7674 C270a Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7675 C270b C270c Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7676 C270d Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7677 C270e Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7678 C270f C270g Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7679 C270h C270j Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7680 C270k C270m Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7681 C270n C270p Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box Relay Box: Application and ID Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7684 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7685 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7686 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7687 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7688 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7689 Relay Box: Application and ID Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7690 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7691 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7692 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7693 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7694 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7695 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7696 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Harness Replacement Guidelines Wiring Harness: Technical Service Bulletins Electrical - Wiring Harness Replacement Guidelines TSB 06-17-8 09/04/06 SERVICE WIRING HARNESS REPLACEMENT GUIDELINES - SERVICE TIPS FORD: 2000-2003 Focus 2005-2006 Focus 2005-2007 Mustang 2002 Ranger 2004-2007 F-150, Freestar 2005 Escape 2005-2007 Expedition 2007 E-Series 2006-2007 F-650, F-750 LINCOLN: 2005-2007 Navigator 2006-2007 Mark LI MERCURY: 2004-2007 Monterey 2005 Mariner This article supersedes TSB 05-16-12 to update vehicle lines and model years. ISSUE Ford Motor Company has "consolidated" high and low content harnesses to make the service selection easier, and to reduce the number of harnesses required for service. Due to this consolidation, service replacement harnesses may or may not look exactly like the production harness being replaced. Service replacement harnesses may come equipped with additional connectors that will not be used. ACTION Should replacement of a production wire harness become necessary, determine whether the harness is to be used in a WET or DRY environment, then refer to the appropriate Service Procedure below. SERVICE PROCEDURE NOTE IF UNSURE WHETHER THE ENVIRONMENT FOR THE HARNESS WILL BE "WET" OR "DRY" ALWAYS TREAT AS A "WET" ENVIRONMENT. Extra Open Connectors - Procedure For "Dry" Environment/Interior Wiring Harness: Any extra open connectors should be tucked, folded, and taped out of the way to avoid creating a rattle or becoming loose (Figure 1). If space allows, Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 7701 position the connectors so they point downward this will avoid the connector catching water in case of a water leak. Extra Open Connectors - Procedure For "Wet" Environment/Exterior Wiring Harness: 1. Cut each wire from the extra connector as close to the connector as possible (Figure 2). 2. Using dual wall heat shrink tubing, position tubing over each individual wire (Figure 3). 3. Use a shielded, flameless heat gun to heat the repair area until the tubing shrinks and adhesive flows out of both ends of the shrink tubing. While the adhesive is still hot, use pliers to pinch the ends of the heat shrink tubing closed to form a moisture proof seal (Figure 4). 4. Use electrical tape to bundle the wires together, then stow the bundle under an existing harness in the area. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 7702 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 7703 Technical Service Bulletin # 05-18-7 Date: 050922 Electrical - Wiring Soldering/Crimping Service Tips TSB 05-18-7 09/22/05 WIRING - SOLDERING AND CRIMPING REPAIRS - SERVICE TIPS FORD: 2000-2006 Crown Victoria, Focus, Mustang, Taurus 2002-2005 Thunderbird 2005-2006 Five Hundred, Ford GT, Freestyle 2006 Fusion 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion 2000-2006 E-Series, Expedition, Explorer, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2000-2006 F-650, F-750 2006 Low Cab Forward LINCOLN: 2000-2006 LS, Town Car 2006 Zephyr 2000-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 2000-2002 Cougar 2000-2005 Sable 2000-2006 Grand Marquis 2005-2006 Montego 2006 Milan 2000-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner 2006 Mariner Hybrid This article supersedes TSB 03-11-6 to update the service procedure, vehicle lines and model years. ISSUE Wire harness repairs are supported through the availability of individual components such as: ^ Wire terminals with machine crimped pigtails ^ Hard shell connectors ^ Dual wall heat shrink tubing ^ Complete, loaded, wiring pigtail kits Some of the available tools and service parts that are helpful when performing wiring harness repairs are: ^ Motorcraft Wiring Pigtail Catalog (see website for more information) ^ Rotunda Wire Splice Tool kit 164-R5903 ^ General Wire Terminal Repair Kit (order through Ford Component Sales) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 7704 Information on the pigtail and terminal repair kits can also be accessed by technicians via the P15 web site. To access on PTS: ^ Select the year/model of the vehicle on the P15 home page ^ Select the wiring tab ^ Select the link to the pigtail or terminal repair kit at the top right of screen. Additional service information contained in this TSB detailing wire folding, soldering, and crimping techniques may be helpful. ACTION REPAIR VS REPLACEMENT The approved procedure is to repair wiring harnesses with pigtail kits, wire terminals, or hard shell connectors when available. The only exceptions to this procedure are when: ^ The repair cost exceeds the cost to replace the wiring harness ^ There are no component parts released to service the wiring harness RESTRAINTS RELATED WIRING REPAIRS If restraints connectors or wiring circuits are contained in a stand-alone harness, do not repair them; replace the restraints harness unless directed to repair the circuit by a TSB or other Ford Motor Company publication. If restraints connectors or wiring circuits are contained in the main vehicle wiring harnesses (14401, 14A005, etc.), they should be repaired using the solder and heat-shrink repair procedure specified in this TSB. The General Wire Terminal Repair Kit contains gold plated terminated pigtails (with white insulation) and dual wall heat shrink tubing to perform these repairs. Loaded wiring pigtail kits with gold plated terminals are also available in the parts catalog. Disclaimer Service Tips Refer to applicable model year wiring diagrams for circuit information. Twisted Wire Circuits For "Twisted Wire" circuit repair (Figure 1), the twisting must not be disrupted for more than 2" (51 mm) Twist the repaired wires in the same direction and with the same general twist rate as the original wiring. Reapply the shielding on shielded circuits. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 7705 Stagger the repairs to minimize harness diameter and maintain harness length (Figure 2). Any leads that are not going to be used need to be sealed with dual wall heat shrink and stowed (Figure 2). Silicone must not be used. Excess wire from the harness can be folded back on itself to maintain the harness length. Reapply any convolute and tape that was removed to make the repair. For 16 AGW and Smaller Diameter Wire Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 7706 1. Strip 1-1/2" (37.2 mm) of insulation from Wire # 1 and 3/4" (19.5 mm) of insulation from Wire # 2, taking care not to nick or cut wire strands (Figure 3). Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. 2. Install heat shrink tubing at least 1" (26 mm) away from one of the stripped ends being spliced. Twist wires together. Solder wires together (Figure 4). NOTE USE ROSIN CORE MILDLY ACTIVATED (RMS) SOLDER. DO NOT USE ACID CORE SOLDER FOR WIRE REPAIR. 3. Bend Wire # 1 back in a straight line for sealing (Figure 4). Inspect solder joint bond. NOTE WAIT FOR SOLDER TO COOL BEFORE MOVING WIRES. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 7707 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 7708 4. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 5. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). For 14 AGW and Larger Diameter Wire (Excluding Restraints Wiring Repairs) 1. Strip 1/4" (6.35 mm) of insulation from pigtail wire end once the wire lengths are sized so repairs can be staggered. Take care not to nick or cut wire strands. Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 7709 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 7710 NOTE THE STRIP LENGTH WILL VARY DEPENDING ON THE BUTT SPLICE AND WIRE IN HARNESS. LONGER STRIP LENGTHS ARE REQUIRED WHEN THE WIRE NEEDS TO BE FOLDED TO MATE WITH THE BUTT SPLICE. REFER TO FIGURE 10 CHART FOR STRIP LENGTHS AND FOLDING TECHNIQUES. 2. Slide heat shrink tubing onto one (1) of the wire ends to be crimped, must be at least 1" (25.4 mm) away from stripped end (Figure 6). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 7711 3. Identify the appropriate crimping chamber of the Rotunda 164-R5901 Pro-Crimper (or equivalent) by matching the wire size on the dies with the wire size stamped on the butt splice (Figure 7). Hold the crimping tool so the identified wire sizes are facing you. Squeeze tool handles together until the ratchet releases, then allow the jaws of the tool to open fully. 4. Center one (1) end of the butt splice on the appropriate crimping chamber. If visible, be sure to place the brazed seam of the butt splice toward the indenter (Figure 8). 5. Hold the butt splice in place and squeeze the tool handles together until the ratchet engages sufficiently to hold the butt splice in position (typically one (1) or two (2) clicks). DO NOT deform the butt splice. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 7712 6. Insert stripped wire into the buff splice, making sure the insulation on wire does not enter the butt splice (Figure 8). 7. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool handles to open, then remove crimped butt splice. 8. To crimp the other half of the splice, reposition the un-crimped wire barrel in the same crimping chamber, and repeat Steps 3-8. If splice cannot be turned for crimping the other half, turn the tool around. 9. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. It is acceptable for crimp to be slightly off center, but not off the end of the buff splice (Figure 9-a). b. Wire insulation does not enter butt splice. Wire is flush with or extends slightly beyond end of buff splice (Figure 9-b). c. Wire is visible through inspection hole of splices (Figure 9-c). 10. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 11. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear C474 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear > Page 7718 C2033 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear > Page 7719 C3063 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear > Page 7720 C3064 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear > Page 7721 C3243 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor 1 C174 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor 1 > Page 7726 C194 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Central Junction Box Fuse: Locations Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Central Junction Box > Page 7731 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Central Junction Box > Page 7732 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Central Junction Box > Page 7733 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Central Junction Box > Page 7734 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Central Junction Box > Page 7735 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Central Junction Box > Page 7736 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Central Junction Box > Page 7737 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Central Junction Box > Page 7738 Fuse: Locations Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Central Junction Box > Page 7739 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Central Junction Box > Page 7740 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Central Junction Box > Page 7741 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Central Junction Box > Page 7742 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Central Junction Box > Page 7743 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7746 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7747 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7748 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7749 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7750 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7751 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7752 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7753 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7754 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7755 Fuse: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7756 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7757 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7758 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7759 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7760 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7761 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7762 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central Junction Box Fuse: Application and ID Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central Junction Box > Page 7765 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central Junction Box > Page 7766 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central Junction Box > Page 7767 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central Junction Box > Page 7768 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central Junction Box > Page 7769 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central Junction Box > Page 7770 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central Junction Box > Page 7771 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central Junction Box > Page 7772 Fuse: Application and ID Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central Junction Box > Page 7773 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central Junction Box > Page 7774 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central Junction Box > Page 7775 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central Junction Box > Page 7776 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Central Junction Box > Page 7777 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central Junction Box Fuse Block: Locations Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central Junction Box > Page 7782 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central Junction Box > Page 7783 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central Junction Box > Page 7784 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central Junction Box > Page 7785 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central Junction Box > Page 7786 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central Junction Box > Page 7787 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central Junction Box > Page 7788 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central Junction Box > Page 7789 Fuse Block: Locations Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central Junction Box > Page 7790 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central Junction Box > Page 7791 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central Junction Box > Page 7792 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central Junction Box > Page 7793 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Central Junction Box > Page 7794 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7797 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7798 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7799 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7800 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7801 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7802 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7803 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7804 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7805 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7806 Fuse Block: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7807 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7808 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7809 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7810 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7811 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7812 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7813 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7814 Fuse Block: Connector Views C270a C270b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7815 C270c C270d Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7816 C270e Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7817 C270f C270g Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7818 C270h C270j Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7819 C270k C270m Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7820 C270n C270p Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Central Junction Box Fuse Block: Application and ID Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 7823 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 7824 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 7825 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 7826 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 7827 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 7828 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 7829 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 7830 Fuse Block: Application and ID Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 7831 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 7832 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 7833 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 7834 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Central Junction Box > Page 7835 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 7839 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 7843 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 Multiple Junction Connector: Diagrams C110-C314 C110 C133 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7848 C134 C144 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7849 C145 C146 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7850 C192 C210 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7851 C211 C212 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7852 C213 C214 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7853 C215 C219 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7854 C237 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7855 C238 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7856 C248 C260 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7857 C263 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7858 C265 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7859 C268 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7860 C291 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7861 C298 C299 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7862 C311 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7863 C312 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7864 C314 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7865 Multiple Junction Connector: Diagrams C315-C2108 C315 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7866 C316 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7867 C327 C328 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7868 C340 C405 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7869 C406 C410 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7870 C411 C421 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7871 C422 C465 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7872 C494 C495 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7873 C510 C610 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7874 C700 C800 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7875 C913 C922 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7876 C925 C934 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7877 C935 C991 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7878 C1010 C1026 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C314 > Page 7879 C2108 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7883 C2110 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7884 Power Distribution Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7885 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 7890 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 7894 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7898 C2110 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7899 Power Distribution Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7900 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box Relay Box: Locations Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7905 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7906 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7907 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7908 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7909 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7910 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7911 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7912 Relay Box: Locations Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7913 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7914 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7915 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7916 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7917 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7918 Relay Box: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7919 C270a Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7920 C270b C270c Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7921 C270d Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7922 C270e Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7923 C270f C270g Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7924 C270h C270j Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7925 C270k C270m Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7926 C270n C270p Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box Relay Box: Application and ID Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7929 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7930 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7931 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7932 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7933 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7934 Relay Box: Application and ID Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7935 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7936 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7937 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7938 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7939 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7940 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7941 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box Relay Box: Locations Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7946 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7947 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7948 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7949 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7950 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7951 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7952 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7953 Relay Box: Locations Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7954 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7955 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7956 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7957 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Central Junction Box > Page 7958 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7959 Relay Box: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7960 C270a Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7961 C270b C270c Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7962 C270d Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7963 C270e Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7964 C270f C270g Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7965 C270h C270j Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7966 C270k C270m Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 7967 C270n C270p Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box Relay Box: Application and ID Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7970 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7971 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7972 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7973 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7974 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7975 Relay Box: Application and ID Passenger Compartment Fuse Panel Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7976 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7977 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7978 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7979 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7980 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7981 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Central Junction Box > Page 7982 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Harness Replacement Guidelines Wiring Harness: Technical Service Bulletins Electrical - Wiring Harness Replacement Guidelines TSB 06-17-8 09/04/06 SERVICE WIRING HARNESS REPLACEMENT GUIDELINES - SERVICE TIPS FORD: 2000-2003 Focus 2005-2006 Focus 2005-2007 Mustang 2002 Ranger 2004-2007 F-150, Freestar 2005 Escape 2005-2007 Expedition 2007 E-Series 2006-2007 F-650, F-750 LINCOLN: 2005-2007 Navigator 2006-2007 Mark LI MERCURY: 2004-2007 Monterey 2005 Mariner This article supersedes TSB 05-16-12 to update vehicle lines and model years. ISSUE Ford Motor Company has "consolidated" high and low content harnesses to make the service selection easier, and to reduce the number of harnesses required for service. Due to this consolidation, service replacement harnesses may or may not look exactly like the production harness being replaced. Service replacement harnesses may come equipped with additional connectors that will not be used. ACTION Should replacement of a production wire harness become necessary, determine whether the harness is to be used in a WET or DRY environment, then refer to the appropriate Service Procedure below. SERVICE PROCEDURE NOTE IF UNSURE WHETHER THE ENVIRONMENT FOR THE HARNESS WILL BE "WET" OR "DRY" ALWAYS TREAT AS A "WET" ENVIRONMENT. Extra Open Connectors - Procedure For "Dry" Environment/Interior Wiring Harness: Any extra open connectors should be tucked, folded, and taped out of the way to avoid creating a rattle or becoming loose (Figure 1). If space allows, Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 7987 position the connectors so they point downward this will avoid the connector catching water in case of a water leak. Extra Open Connectors - Procedure For "Wet" Environment/Exterior Wiring Harness: 1. Cut each wire from the extra connector as close to the connector as possible (Figure 2). 2. Using dual wall heat shrink tubing, position tubing over each individual wire (Figure 3). 3. Use a shielded, flameless heat gun to heat the repair area until the tubing shrinks and adhesive flows out of both ends of the shrink tubing. While the adhesive is still hot, use pliers to pinch the ends of the heat shrink tubing closed to form a moisture proof seal (Figure 4). 4. Use electrical tape to bundle the wires together, then stow the bundle under an existing harness in the area. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 7988 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 7989 Technical Service Bulletin # 05-18-7 Date: 050922 Electrical - Wiring Soldering/Crimping Service Tips TSB 05-18-7 09/22/05 WIRING - SOLDERING AND CRIMPING REPAIRS - SERVICE TIPS FORD: 2000-2006 Crown Victoria, Focus, Mustang, Taurus 2002-2005 Thunderbird 2005-2006 Five Hundred, Ford GT, Freestyle 2006 Fusion 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion 2000-2006 E-Series, Expedition, Explorer, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2000-2006 F-650, F-750 2006 Low Cab Forward LINCOLN: 2000-2006 LS, Town Car 2006 Zephyr 2000-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 2000-2002 Cougar 2000-2005 Sable 2000-2006 Grand Marquis 2005-2006 Montego 2006 Milan 2000-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner 2006 Mariner Hybrid This article supersedes TSB 03-11-6 to update the service procedure, vehicle lines and model years. ISSUE Wire harness repairs are supported through the availability of individual components such as: ^ Wire terminals with machine crimped pigtails ^ Hard shell connectors ^ Dual wall heat shrink tubing ^ Complete, loaded, wiring pigtail kits Some of the available tools and service parts that are helpful when performing wiring harness repairs are: ^ Motorcraft Wiring Pigtail Catalog (see website for more information) ^ Rotunda Wire Splice Tool kit 164-R5903 ^ General Wire Terminal Repair Kit (order through Ford Component Sales) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 7990 Information on the pigtail and terminal repair kits can also be accessed by technicians via the P15 web site. To access on PTS: ^ Select the year/model of the vehicle on the P15 home page ^ Select the wiring tab ^ Select the link to the pigtail or terminal repair kit at the top right of screen. Additional service information contained in this TSB detailing wire folding, soldering, and crimping techniques may be helpful. ACTION REPAIR VS REPLACEMENT The approved procedure is to repair wiring harnesses with pigtail kits, wire terminals, or hard shell connectors when available. The only exceptions to this procedure are when: ^ The repair cost exceeds the cost to replace the wiring harness ^ There are no component parts released to service the wiring harness RESTRAINTS RELATED WIRING REPAIRS If restraints connectors or wiring circuits are contained in a stand-alone harness, do not repair them; replace the restraints harness unless directed to repair the circuit by a TSB or other Ford Motor Company publication. If restraints connectors or wiring circuits are contained in the main vehicle wiring harnesses (14401, 14A005, etc.), they should be repaired using the solder and heat-shrink repair procedure specified in this TSB. The General Wire Terminal Repair Kit contains gold plated terminated pigtails (with white insulation) and dual wall heat shrink tubing to perform these repairs. Loaded wiring pigtail kits with gold plated terminals are also available in the parts catalog. Disclaimer Service Tips Refer to applicable model year wiring diagrams for circuit information. Twisted Wire Circuits For "Twisted Wire" circuit repair (Figure 1), the twisting must not be disrupted for more than 2" (51 mm) Twist the repaired wires in the same direction and with the same general twist rate as the original wiring. Reapply the shielding on shielded circuits. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 7991 Stagger the repairs to minimize harness diameter and maintain harness length (Figure 2). Any leads that are not going to be used need to be sealed with dual wall heat shrink and stowed (Figure 2). Silicone must not be used. Excess wire from the harness can be folded back on itself to maintain the harness length. Reapply any convolute and tape that was removed to make the repair. For 16 AGW and Smaller Diameter Wire Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 7992 1. Strip 1-1/2" (37.2 mm) of insulation from Wire # 1 and 3/4" (19.5 mm) of insulation from Wire # 2, taking care not to nick or cut wire strands (Figure 3). Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. 2. Install heat shrink tubing at least 1" (26 mm) away from one of the stripped ends being spliced. Twist wires together. Solder wires together (Figure 4). NOTE USE ROSIN CORE MILDLY ACTIVATED (RMS) SOLDER. DO NOT USE ACID CORE SOLDER FOR WIRE REPAIR. 3. Bend Wire # 1 back in a straight line for sealing (Figure 4). Inspect solder joint bond. NOTE WAIT FOR SOLDER TO COOL BEFORE MOVING WIRES. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 7993 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 7994 4. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 5. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). For 14 AGW and Larger Diameter Wire (Excluding Restraints Wiring Repairs) 1. Strip 1/4" (6.35 mm) of insulation from pigtail wire end once the wire lengths are sized so repairs can be staggered. Take care not to nick or cut wire strands. Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 7995 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 7996 NOTE THE STRIP LENGTH WILL VARY DEPENDING ON THE BUTT SPLICE AND WIRE IN HARNESS. LONGER STRIP LENGTHS ARE REQUIRED WHEN THE WIRE NEEDS TO BE FOLDED TO MATE WITH THE BUTT SPLICE. REFER TO FIGURE 10 CHART FOR STRIP LENGTHS AND FOLDING TECHNIQUES. 2. Slide heat shrink tubing onto one (1) of the wire ends to be crimped, must be at least 1" (25.4 mm) away from stripped end (Figure 6). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 7997 3. Identify the appropriate crimping chamber of the Rotunda 164-R5901 Pro-Crimper (or equivalent) by matching the wire size on the dies with the wire size stamped on the butt splice (Figure 7). Hold the crimping tool so the identified wire sizes are facing you. Squeeze tool handles together until the ratchet releases, then allow the jaws of the tool to open fully. 4. Center one (1) end of the butt splice on the appropriate crimping chamber. If visible, be sure to place the brazed seam of the butt splice toward the indenter (Figure 8). 5. Hold the butt splice in place and squeeze the tool handles together until the ratchet engages sufficiently to hold the butt splice in position (typically one (1) or two (2) clicks). DO NOT deform the butt splice. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Harness Replacement Guidelines > Page 7998 6. Insert stripped wire into the buff splice, making sure the insulation on wire does not enter the butt splice (Figure 8). 7. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool handles to open, then remove crimped butt splice. 8. To crimp the other half of the splice, reposition the un-crimped wire barrel in the same crimping chamber, and repeat Steps 3-8. If splice cannot be turned for crimping the other half, turn the tool around. 9. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. It is acceptable for crimp to be slightly off center, but not off the end of the buff splice (Figure 9-a). b. Wire insulation does not enter butt splice. Wire is flush with or extends slightly beyond end of buff splice (Figure 9-b). c. Wire is visible through inspection hole of splices (Figure 9-c). 10. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 11. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications Total Alignment: Specifications Alignment Specifications Total ALIGNMENT SPECIFICATIONS FRONT COIL SPRING SUSPENSION CAMBER LH ........................................................................................................................................................ ...................................................... -0.3° ± 0.75° RH ........................................................................... .................................................................................................................................. -0.3° ± 0.75° Total/Split ............................................................................................................................................. ......................................................... 0° ± 0.75° CASTER LH ........................................................................................................................................................ ......................................................... 5.3° ± 1.0° RH ........................................................................... ...................................................................................................................................... 5.3° ± 1.0° Total/Split ............................................................................................................................................. ......................................................... 0° ± 0.75° TOE @ CURB RIDE HEIGHT LH ........................................................................................................................................................ ...................................................................... --- RH ............................................................................ .................................................................................................................................................. --Total/Split ............................................................................................................................................. .................................................... 0.14° ± 0.20° NOTE: Positive value is toe-in, negative value is toe-out. FRONT AIR SUSPENSION CAMBER LH ........................................................................................................................................................ ............................................ -0.6°/ -0.3° ± 0.75° RH ............................................................................ ....................................................................................................................... -0.6°/ -0.3° ± 0.75° Total/Split ............................................................................................................................................. ......................................................... 0° ± 0.75° CASTER LH ........................................................................................................................................................ ................................................. 5.5°/5.4° ± 1.0° RH ............................................................................ ............................................................................................................................. 5.5°/5.4° ± 1.0° Total/Split ............................................................................................................................................. ......................................................... 0° ± 0.75° TOE @ TRIM RIDE HEIGHT LH ........................................................................................................................................................ ...................................................................... --- RH ............................................................................ .................................................................................................................................................. --Total/Split ............................................................................................................................................. .................................................... 0.14° ± 0.20° NOTE: Positive value is toe-in, negative value is toe-out. REAR COIL SPRING SUSPENSION CAMBER LH ........................................................................................................................................................ ...................................................... -0.9° ± 0.75° RH ........................................................................... .................................................................................................................................. -0.9° ± 0.75° Total/Split ............................................................................................................................................. ......................................................... 0° ± 0.75° TOE @ CURB RIDE HEIGHT LH ........................................................................................................................................................ ...................................................................... --- RH ............................................................................ .................................................................................................................................................. --Total/Split ............................................................................................................................................. .................................................... 0.20° ± 0.20° NOTE: Positive value is toe-in, negative value is toe-out. REAR AIR SUSPENSION CAMBER LH ........................................................................................................................................................ ...................................................... -1.0° ± 0.75° RH ........................................................................... .................................................................................................................................. -1.0° ± 0.75° Total/Split ............................................................................................................................................. ......................................................... 0° ± 0.75° TOE @ TRIM RIDE HEIGHT LH ........................................................................................................................................................ ...................................................................... --- RH ............................................................................ .................................................................................................................................................. --Total/Split ............................................................................................................................................. .................................................... 0.20° ± 0.20° Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications Total > Page 8004 NOTE: Positive value is toe-in, negative value is toe-out. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications Total > Page 8005 Torque Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 8006 Alignment: Description and Operation Wheel Alignment Angles The front caster and camber are adjusted by removing the lower arm front and rear bolts and installing adjuster kits to allow the arm to be adjusted in the frame slots. Front toe is adjusted by the use of the front wheel knuckle tie-rods. The rear camber is adjusted by positioning the upper arm-to-knuckle bolt in the upper arm-to-knuckle slot. The rear toe is adjusted by the use of the rear toe links. Camber Negative and Positive Camber Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or negative and has a direct effect on tire wear. Caster Caster Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed from the side. The caster specifications will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting does not effect tire wear. Toe Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 8007 Positive Toe (Toe In) Negative Toe (Toe Out) The vehicle toe setting: ^ affects tire wear and directional stability. ^ must be checked after adding aftermarket equipment, such as a snowplow. Ride Height NOTE: Air suspension vehicles must be at trim height prior to measuring the vehicle ride height. Front Ride Height Measurement Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 8008 Rear Ride Height Measurement Wheel Track Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 8009 Dogtracking Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can give the illusion of dogtracking. Wander Wander is the tendency of the vehicle to require frequent, random left and right steering wheel corrections to maintain a straight path down a level road. Shimmy Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel resulting from large, side-to-side (lateral) tire/wheel movements. Shimmy is usually experienced near 64 km/h (40 mph), and can begin or be amplified when the tire contacts pot holes or irregularities in the road surface. Nibble Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road surfaces or tire imbalance. This condition is observed by the driver as small rotational oscillations of the steering wheel. Poor Returnability/Sticky Steering Poor returnability and sticky steering is used to describe the poor return of the steering wheel to center after a turn or when the steering correction is completed. Drift/Pull Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep the vehicle going straight. Drift describes what a vehicle with this condition does with hands off the steering wheel. ^ A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead path and require constant steering input in the opposite direction to counteract the effect ^ Drift/Pull may be induced by conditions external to the vehicle (such as wind or road camber). Poor Groove Feel Poor groove feel is, characterized by little or no buildup of turning effort felt in the steering wheel as the wheel is rocked slowly left and right within very small turns around center or straight-ahead (under 20 degrees of steering wheel turn). Efforts may be said to be "flat on center." ^ Under 20 degrees of turn, most of the turning effort that builds up comes from the mesh of gear teeth in the steering gear. In this range, the steering wheel is not yet turned enough to feel the effort from the self-aligning forces at the road wheel or tire patch. ^ In the diagnosis of a steering or alignment concern, it is important to understand the difference between wander and poor groove feel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment Front Alignment: Service and Repair Camber and Caster Adjustment Front Camber and Caster Adjustment Front NOTE: Air suspension vehicles must be at trim ride height prior to measuring or adjusting the caster, camber or toe. 1. Using alignment equipment and the manufacturers instructions, measure the front caster and camber. ^ Refer to Alignment Specifications for optimal alignment settings. ^ If the caster and camber values are not within specification, go to the next step. 2. Remove and discard the lower arm front and rear nuts and bolts. 3. NOTE: New lower arm front and rear bolts must be installed with cam bolt kits (2L1Z-3B236-AC for front bushing; and 2L1Z-3B236-AD for rear bushing), to allow for adjustment of the arm in the frame slot. The vehicle should be supported by the frame to ease movement of the lower arm in the slot. Install the cam bolt kit and loosely install the nut. 4. To adjust the caster and camber, refer to the following chart. ^ Adjustments that require moving the front and the rear of the lower arm should be made equally. 5. While holding the cam bolt, tighten the nut to 270 Nm (199 ft. lbs.). 6. Cheek and, if necessary, adjust the front toe. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment Front > Page 8012 Alignment: Service and Repair Front Toe Adjustment Front Toe Adjustment NOTE: Air suspension vehicles must be at trim ride height prior to measuring or adjusting the caster, camber or toe. 1. Using alignment equipment and the manufacturers instructions, measure the front toe. ^ Refer to Alignment Specifications for optimal alignment settings. ^ If the front toe values are not within specification, go to the next step. 2. Start the engine and center the steering wheel. 3. Turn the engine off and, using a suitable steering wheel holding device, lock the steering wheel in the straight-ahead position. 4. Remove the steering gear bellows clamp(s). 5. Loosen the tie-rod end jam nut(s). 6. NOTE: Do not allow the steering gear bellows to twist while rotating the tie-rod. Rotate the tie-rod(s) to achieve the desired toe setting. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment Front > Page 8013 7. CAUTION: Make sure to hold the tie-rod end stationary while tightening the jam nut or damage to the boot can occur. NOTE: Make sure that the toe settings are not disturbed while tightening the jam nuts. Tighten the tie-rod end jam nut(s) to 103 Nm (76 ft. lbs.). 8. Install the steering gear bellows clamp(s). 9. Start the engine and center the steering wheel. ^ Recheck the toe settings and adjust as necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment Front > Page 8014 Alignment: Service and Repair Camber Adjustment - Rear Camber Adjustment - Rear NOTE: Air suspension vehicles must be at trim ride height prior to measuring or adjusting the rear camber or toe. 1. Using alignment equipment and the manufacturers instructions, measure the rear caster. ^ Refer to Alignment Specifications for optimal alignment settings. ^ If the rear caster value is not within specification, go to the next step. 2. Determine desired camber adjustment (subtract the specified camber angle from the measured camber angle). 3. Mark a scribe line on the upper arm-to-wheel knuckle bolt head and upper arm. Desired Camber Adjustment (In Degrees) (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment Front > Page 8015 Desired Camber Adjustment (In Degrees) (Part 2) 4. Use the following table to determine the camber adjustment required. Obtained by subtracting the specified camber angle from the measure camber angle. 5. Remove the upper arm-to-knuckle nut and install a new one until snug. 6. NOTE: Support the vehicle at the lower arm to ease the wheel knuckle movement in the upper arm slot. Position the upper arm-to-knuckle bolt in the upper arm slot as required to adjust the camber angle to the value obtained in Step 4. 7. Tighten the upper arm-to-knuckle nut to 150 Nm (111 ft. lbs.). 8. Recheck the camber setting, adjust as necessary. 9. Check and, if necessary, adjust the rear toe. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment Front > Page 8016 Alignment: Service and Repair Rear Toe Adjustment Rear Toe Adjustment NOTE: Air suspension vehicles must be at trim ride height prior to measuring or adjusting the rear toe. 1. Using alignment equipment and the manufacturers instructions, measure the rear toe. ^ Refer to Alignment Specifications for optimal alignment settings. ^ If the rear toe values are not within specification, go to the next step. 2. Loosen the toe link jam nut(s). 3. Rotate the toe link tie-rod to achieve the desired toe setting. 4. NOTE: Make sure the toe settings are not disturbed while tightening the jam nuts. Tighten the toe link jam nut(s) to 115 Nm (85 ft. lbs.). 5. Recheck the rear toe setting, adjust as necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment Front > Page 8017 Alignment: Service and Repair Ride Height Adjustments Ride Height Adjustments Special Tools Inflation and Deflation of the Air Suspension System 1. NOTE: Make sure that the air suspension switch is in the ON position. NOTE: Make sure that a battery voltage of at least 11 volts is maintained while carrying out this procedure. Turn the ignition switch to the ON position. 2. Connect the diagnostic tool to the data link connector (DLC). 3. Select Air Suspension Control Module under Active Command Mode. 4. Follow the diagnostic tool directions to lift or vent the front or rear suspension. Calibration Ride Height Resetting 1. NOTE: Make sure that the air suspension switch is in the ON position. NOTE: Make sure that a battery voltage of at least 11 volts is maintained while carrying out this procedure. Turn the ignition to the OFF position. Exit the vehicle, close all doors and allow the system to vent the vehicle down to kneel height (approximately 45 seconds). 2. With the ignition in the ON position, shift the vehicle into DRIVE and then back to PARK. Exit the vehicle, close all doors and allow the vehicle to pump to trim (approximately 45 seconds). 3. Measure the ride height. 4. Open the LF door. 5. Connect the diagnostic tool to the data link connector (DLC). 6. While outside of the vehicle, select the correct vehicle year, model and engine type. 7. Select vehicle dynamic module (VDM). 8. Using the active command mode, vent or lift the vehicle to achieve the correct ride height. 9. Select the "Save Calibration Values (Store Ride Height)" diagnostic tool command to calibrate the VDM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 8023 C1300 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 8024 Compressor/Pump Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 8025 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations Suspension Control Module: Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 8029 View 151-15 (LH A-Pillar) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 8030 Suspension Control Module: Diagrams C2131a C2131b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 8031 C2324a C2324b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 8032 Suspension Control Module: Service and Repair Air Suspension Control Module Removal and Installation 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable. 2. NOTE: The air suspension control module is mounted to the lower left side of the dash above the parking brake control. Disconnect the 2 air suspension control module electrical connectors. 3. Pull back the dash padding to expose the 2 module bracket nuts. 4. Remove the air suspension control module nuts and the air suspension control module. ^ To install, tighten to 8 Nm (71 inch lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 8033 5. NOTE: The air suspension control module is calibrated with information from the ride height sensors. A new or exchanged air suspension control module requires that the ride height adjustment calibration and pneumatic test be carried out. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Service and Repair Tire Pressure Module: Service and Repair Tire Pressure Monitoring System Module Removal and Installation CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: The tire pressure monitoring system (TPM's) is integral to the vehicle security module (VSM) and is not serviced separately. NOTE: A new VSM module is delivered in manufacturing mode with pre-set diagnostic trouble codes (DTC's). These DTC's require that a particular set of operations to be carried out in order to clear them and enable the module for normal operations. The pre-set DTC's are as follows: ^ B2477 - Module Configuration Failure/Mismatch ^ B2868 - Left Front Tire Pressure Sensor Fault ^ B2869 - Right Front Tire Pressure Sensor Fault ^ B2870 - Left Rear Tire Pressure Sensor Fault ^ B2871 - Right Rear Tire Pressure Sensor Fault ^ C2780 - ECU in Manufacturing Mode NOTE: A re-configured VSM may also set the above codes and will need to go through the same set of procedures as a new module to enable normal operation. 1. NOTE: The steps included in the VSM removal and installation process are critical to restoring vehicle security and tire pressure monitoring system operations and will permit a new or reconfigured module to operate as intended. Each step is designed to carry out a particular operation and clear the manufacturing mode DTC's. Once these DTC's are cleared, the new or reconfigured module will enter into normal operating mode. Remove the VSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch POWER STEERING PRESSURE (PSP) SWITCH Typical Power Steering Pressure (PSP) Switch The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch > Page 8044 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor POWER STEERING PRESSURE (PSP) SENSOR Typical Power Steering Pressure (PSP) Sensor The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM changes as the hydraulic pressure changes. The PCM uses the input signal from the PSP sensor to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP sensor signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations View 151-14 (Steering Column) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 8048 C226 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins > Customer Interest: > 06-15-10 > Aug > 06 > Suspension - Air Suspension Height Sensor Linkage Loose Ride Height Sensor: Customer Interest Suspension - Air Suspension Height Sensor Linkage Loose TSB 06-15-10 08/07/06 AIR SUSPENSION PERFORMANCE - HEIGHT SENSOR LINKAGE ARM DISENGAGING FORD: 2003-2006 Expedition LINCOLN: 2003-2006 Navigator ISSUE Some 2003-2006 Expedition and Navigator vehicles equipped with an air suspension may exhibit an air suspension height sensor linkage arm disengaging from the suspension ball stud or height sensor rotating arm. This concern typically occurs with the rear sensor (Figure 1) but may occur with the front sensors as well. If this occurs, the symptom will typically be the vehicle leaning to one side, the vehicle sitting too low/high, a harsh ride, and/or an inoperative air suspension. In addition, this concern may result in diagnostic trouble code (DTC) C1725 (air suspension front pneumatic failure) or C1726 (air suspension rear pneumatic failure). ACTION When a linkage arm becomes disengaged, do not re-attach the arm and do not replace the sensor unless broken. Instead, install a revised linkage arm on all three (3) sensor assemblies, even if they have not detached from the ball stud. Refer to the following Service Procedure. SERVICE PROCEDURE Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins > Customer Interest: > 06-15-10 > Aug > 06 > Suspension - Air Suspension Height Sensor Linkage Loose > Page 8058 NOTE LINKAGE ARMS USED AS ORIGINAL EQUIPMENT ARE SHOWN IN FIGURE 2. REVISED LINKAGE ARMS (FIGURE 3) HAVE A NEW DESIGN THAT MAKES IT MORE DIFFICULT TO DISENGAGE FROM THE BALL STUDS. NOTE IF THE SENSOR ASSEMBLY NEEDS TO BE REPLACED FOR ANY DAMAGE/FAILURE OTHER THAN THE ONE DESCRIBED IN THIS TSB, THE REPLACEMENT ASSEMBLY IS SUPPLIED WITH A NEW STYLE LINKAGE ARM, SO THERE IS NO NEED TO ORDER ADDITIONAL LINKAGES FOR THE SERVICE REPAIR. 1. Replace linkage arms on all three (3) sensor assemblies following Workshop Manual (WSM), Section 204-05. 2. Discard the old linkage arms. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061510A 2003-2006 0.4 Hr. Expedition/Navigator: Replace The Three Linkage Arms, Includes Time To Check Diagnostic Trouble Codes (Do Not Use With 5300A, 5300A7, 5300A8) DEALER CODING CONDITION BASIC PART NO. CODE 5A967 07 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-15-10 > Aug > 06 > Suspension - Air Suspension Height Sensor Linkage Loose Ride Height Sensor: All Technical Service Bulletins Suspension - Air Suspension Height Sensor Linkage Loose TSB 06-15-10 08/07/06 AIR SUSPENSION PERFORMANCE - HEIGHT SENSOR LINKAGE ARM DISENGAGING FORD: 2003-2006 Expedition LINCOLN: 2003-2006 Navigator ISSUE Some 2003-2006 Expedition and Navigator vehicles equipped with an air suspension may exhibit an air suspension height sensor linkage arm disengaging from the suspension ball stud or height sensor rotating arm. This concern typically occurs with the rear sensor (Figure 1) but may occur with the front sensors as well. If this occurs, the symptom will typically be the vehicle leaning to one side, the vehicle sitting too low/high, a harsh ride, and/or an inoperative air suspension. In addition, this concern may result in diagnostic trouble code (DTC) C1725 (air suspension front pneumatic failure) or C1726 (air suspension rear pneumatic failure). ACTION When a linkage arm becomes disengaged, do not re-attach the arm and do not replace the sensor unless broken. Instead, install a revised linkage arm on all three (3) sensor assemblies, even if they have not detached from the ball stud. Refer to the following Service Procedure. SERVICE PROCEDURE Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-15-10 > Aug > 06 > Suspension - Air Suspension Height Sensor Linkage Loose > Page 8064 NOTE LINKAGE ARMS USED AS ORIGINAL EQUIPMENT ARE SHOWN IN FIGURE 2. REVISED LINKAGE ARMS (FIGURE 3) HAVE A NEW DESIGN THAT MAKES IT MORE DIFFICULT TO DISENGAGE FROM THE BALL STUDS. NOTE IF THE SENSOR ASSEMBLY NEEDS TO BE REPLACED FOR ANY DAMAGE/FAILURE OTHER THAN THE ONE DESCRIBED IN THIS TSB, THE REPLACEMENT ASSEMBLY IS SUPPLIED WITH A NEW STYLE LINKAGE ARM, SO THERE IS NO NEED TO ORDER ADDITIONAL LINKAGES FOR THE SERVICE REPAIR. 1. Replace linkage arms on all three (3) sensor assemblies following Workshop Manual (WSM), Section 204-05. 2. Discard the old linkage arms. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061510A 2003-2006 0.4 Hr. Expedition/Navigator: Replace The Three Linkage Arms, Includes Time To Check Diagnostic Trouble Codes (Do Not Use With 5300A, 5300A7, 5300A8) DEALER CODING CONDITION BASIC PART NO. CODE 5A967 07 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ride Height Sensor: > 05-16-11 > Aug > 05 > Restraints - Seat Belts Slow to Retract Seat Belt Retractor: All Technical Service Bulletins Restraints - Seat Belts Slow to Retract TSB 05-16-11 08/22/05 SAFETY BELT RETRACTION SPEED FORD: 2000-2003 Mustang 2000-2006 Crown Victoria, Taurus 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion, Explorer 2000-2006 E-Series, Expedition, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2004-2006 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 LS, Town Car, Navigator 2003-2005 Aviator MERCURY: 2000-2005 Sable 2000-2006 Grand Marquis 2000-2005 Mountaineer 2004-2006 Monterey 2005-2006 Mariner This article supersedes TSB 04-24-21 to update the vehicle model years. ISSUE A service kit is now available to improve safety belt retraction speed. ACTION See the part application chart and select the appropriate kit. Follow the Instruction Sheet included in the kit. Refer to Workshop Manual Section 501-20A for additional information. NOTE TEFLON TAPE SHOULD ONLY BE USED ON THE FRONT ROW SEATS FOR VEHICLES LISTED IN THIS TSB, WITH THE EXCEPTION OF THE AVIATOR, EXPLORER 4DR AND THE MOUNTAINEER. TEFLON TAPE CAN ALSO BE USED ON SECOND ROW SEATS FOR THESE THREE VEHICLES. NOTE FOR MUSTANG, AVIATOR, EXPLORER 4DR AND MOUNTAINEER, REFER TO THE FOLLOWING BUILD DATE INFORMATION BEFORE PERFORMING THIS TSB. TEFLON TAPE HAS ALREADY BEEN INSTALLED DURING PRODUCTION ON SOME OF THESE VEHICLES. ^ MUSTANG: Only install on vehicles built through 6/15/2003. Teflon tape was already installed on vehicles built on/after 6/16/2003. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (FRONT ROW SEATS): Only install on vehicles built through 6/24/2004. Teflon tape was already installed on vehicles built on/after 6/25/2004. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (SECOND ROW SEATS): Only install on vehicles built through 10/21/2004. Teflon tape was already installed on vehicles built on/after 10/22/2004. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ride Height Sensor: > 05-16-11 > Aug > 05 > Restraints - Seat Belts Slow to Retract > Page 8070 Parts Block NOTE THE LABOR OPERATIONS WITHIN THIS TSB CAN BE CLAIMED IN COMBINATION AS NEEDED TO COVER THE REQUIRED REPAIRS. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051611A Install Teflon Tape B 0.8 Hr. Pillars Both Sides (Includes Time To Remove And Install Trim Panels If Necessary) 051611B Install Teflon Tape C 1.1 Hrs. Pillars Both Sides (Includes Time To Remove And Install Trim Panels And Seats If Necessary) DEALER CODING CONDITION BASIC PART NO. CODE 70611B08 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ride Height Sensor: > 05-16-11 > Aug > 05 > Restraints - Seat Belts Slow to Retract > Page 8076 Parts Block NOTE THE LABOR OPERATIONS WITHIN THIS TSB CAN BE CLAIMED IN COMBINATION AS NEEDED TO COVER THE REQUIRED REPAIRS. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051611A Install Teflon Tape B 0.8 Hr. Pillars Both Sides (Includes Time To Remove And Install Trim Panels If Necessary) 051611B Install Teflon Tape C 1.1 Hrs. Pillars Both Sides (Includes Time To Remove And Install Trim Panels And Seats If Necessary) DEALER CODING CONDITION BASIC PART NO. CODE 70611B08 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins > Page 8077 Ride Height Sensor: Service and Repair Suspension Height Sensor Front Height Sensor Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins > Page 8078 Rear Height Sensor Removal and Installation 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 LH quarter trim panel. 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. All sensors 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the sensor arm from the vehicle. Front sensor 3. Remove and discard the 2 sensor nuts. ^ To install, tighten to 30 Nm (22 ft. lbs.). Rear sensor 4. Remove and discard the sensor nuts and bolts. ^ To install, tighten to 15 Nm (13 ft. lbs.). All sensors 5. Disconnect the sensor electrical connector. 6. NOTE: The RH and LH height sensors cannot be used on opposite sides of the vehicle. To install, reverse the removal procedure. 7. Calibrate the height sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations View 151-14 (Steering Column) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 8082 C226 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Locations View 151-19 (Left Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Locations > Page 8086 C4169 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection Tire Pressure Sensor: Testing and Inspection Sensor Training (Reset Procedure) NOTE: The tire pressure monitoring system is not affected by wheel and tire rotation. NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area without radio frequency (RF) noise. RF noise is generated by electrical motor and appliance operation, cellular telephones and remote transmitters, power inverters and portable entertainment equipment. 1. Turn the ignition switch to the OFF position. 2. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. Do not wait more than 1 minute between each key cycle. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. Do not wait more than 1 minute between each key cycle. 6. The horn will sound once and the TPMS indicator will flash if train mode has been entered successfully. If equipped, the message center displays "TRAIN LF TIRE", place the special tool on the valve stem of the LF tire pressure sensor. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the TPMS module. 7. Within 2 minutes after the horn sounds, place the special tool on the valve stem of the RF tire pressure sensor. NOTE: If the VSM (TPMS module integral to VSM) does not recognize any 1 of the 4 tire pressure sensors during the tire training procedure, the horn will sound twice and the message center (if equipped) will display "TIRE NOT TRAINED REPEAT" and the procedure must be repeated. 8. Repeat Step 7 for the RR and LR tires. When the tire training procedure is complete, the horn will sound once and the message center (if equipped) will display "TIRE TRAINING MODE COMPLETE". Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 8091 Tire Pressure Sensor: Service and Repair Tire Pressure Sensor Special Tools CAUTION: Use only special tool 204-354 anytime tire pressures are measured to be sure that accurate values are obtained. CAUTION: Place the air chuck straight on the valve stem to inflate the tire. Do not cock the air chuck during the inflation cycle. Doing so can damage the valve stem and cause air leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 8092 CAUTION: Ford recommends using a round head air chuck on tire pressure sensors; it is not recommended to use air chucks with long shanks. Doing so can cause tire pressure sensor valve stem damage and loss of tire pressure. Removal NOTE: The vehicle is equipped with a light blue-colored tire pressure sensor. When installing new components, use only this tire pressure sensor. The tire pressure monitoring system (TPM's) will not operate correctly if black-colored tire pressure sensors are installed. 1. Remove the wheel and tire assembly. 2. CAUTION: Do not remove the valve stem core to relieve the tire pressure. CAUTION: If the valve stem core has been removed from the valve stem, reinstall the original valve stem core. If the original valve stem core is damaged, a nickel-plated core must be installed. Failure to use a nickel-plated core will result in corrosion and the possible loss of tire pressure. NOTE: Release the tire pressure by removing the sensor valve stem nut. With the valve stem at the 6 o'clock position, remove the sensor valve stem nut and push the sensor by hand into the tire (with the cap on). 3. Using a suitable tire machine, separate both beads of the tire from the wheel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 8093 4. CAUTION: Care should be taken not to damage the tire pressure sensor while separating the outside bead of tire from the wheel. Place the wheel and tire on the turntable of the tire machine, index-mark the valve stem and wheel weight positions, lubricate the bead of the tire and dismount the outside bead of the tire from the wheel. 5. Remove the tire pressure sensor from the tire. 6. Remove and discard the grommet from the tire pressure sensor. Installation NOTE: The vehicle is equipped with a light blue-colored tire pressure sensor. When installing new components, use only this tire pressure sensor. The TPM's will not operate correctly if black-colored tire pressure sensors are installed. 1. NOTE: Install a new sensor grommet or an air leak can occur. Install a new grommet on the tire pressure sensor. 2. NOTE: Do not allow the tire to rotate relative to the rim while mounting the tire. Lubricate and mount the outside and inside bead of the tire to the rim. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 8094 3. CAUTION: Overtightening the tire pressure sensor valve stem nut can damage the tire pressure sensor, undertightening can cause air leaks. NOTE: Sensor position is critical for correct sensor operation. The "flat" side of the sensor must be facing the wheel and the "slanted" side of the sensor must be facing away from the wheel. When properly installed, there will be a very small gap between the sensor and the wheel. NOTE: Tightening the nut to 5 Nm (44 inch lbs.) equals approximately 2 clockwise turns after the nut has been tightened by hand. Push the side wall of the tire and install the tire pressure sensor. Tighten the nut to 5 Nm (44 inch lbs.). 4. CAUTION: Use only special tool 204-354 anytime tire pressures are measured to be sure that accurate values are obtained. CAUTION: Place the air chuck straight on the valve stem to inflate the tire. Do not cock the air chuck during the inflation cycle. Doing so can damage the valve stem and cause air leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 8095 CAUTION: Ford recommends using a round head air chuck on tire pressure sensors; it is not recommended to use air chucks with long shanks. Doing so can cause tire pressure sensor valve stem damage and loss of tire pressure. CAUTION: Use only OEM valve caps (aluminum or plastic valve caps) with the tire pressure sensors. Do not use brass-threaded valve caps with the tire pressure sensors. Inflate the tire to the pressure specified on the safety certification sticker located on the driver or door pillar. 5. Install the wheel and tire assembly. 6. Train the tire pressure sensors. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Front Front Steering Knuckle: Service and Repair Front Wheel Knuckle Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Front > Page 8101 service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Remove the wheel hub. 2. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut. Remove the tie-rod end nut and detach the tie-rod end from the wheel knuckle. ^ Discard the nut. ^ To install, tighten to 150 Nm (111 ft. lbs.). 3. Remove the brake hose bracket bolt and position the brake hose aside. ^ To install, tighten to 12 Nm (9 ft. lbs.). 4. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut. Remove and discard the stabilizer bar link lower nut. ^ To install, tighten to 90 Nm (66 ft. lbs.). 5. Remove the shock absorber lower nut and bolt. ^ Discard the nut. ^ To install, tighten to 475 Nm (350 ft. lbs.). 6. Remove the 3 integrated wheel end disconnect bolts. ^ To install, tighten to 15 Nm (11 ft. lbs.). 7. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut. NOTE: To separate the ball joint from the wheel knuckle, loosely install the nut and then tap on the end of the stud. Remove the lower ball joint nut and separate the ball Joint from the knuckle. ^ Discard the nut. ^ To install, tighten to 200 Nm (148 ft. lbs.). 8. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut. Remove the upper ball Joint nut and the wheel knuckle. ^ Discard the nut. ^ To install, tighten to 150 Nm (111 ft. lbs.). 9. If necessary, remove the 3 brake disc shield bolts and remove the brake disc shield. ^ To install, tighten to 12 Nm (9 ft. lbs.). 10. To install, reverse the removal procedure. 11. Check and, if necessary, align the front end. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Front > Page 8102 Front Steering Knuckle: Service and Repair Rear Wheel Knuckle Removal and Installation 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 LH rear quarter trim panel. 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. Failure to follow these instructions may result in personal injury. CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Remove the wheel bearing and hub assembly. 2. Remove the parking brake shoe retaining clips, adjuster spring, return spring, adjuster and the parking brake shoes. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Front > Page 8103 3. Depress the tabs and detach the parking brake cable from the wheel knuckle. 4. Remove the toe link-to-wheel knuckle nut and detach the toe link from the wheel knuckle. ^ Discard the nut. ^ To install, tighten to 55 Nm (41 ft. lbs.). 5. Remove the upper arm-to-wheel knuckle nut and bolt. ^ Discard the nut. ^ To install, tighten to 150 Nm (111 ft. lbs.). 6. Remove the lower arm-to-wheel knuckle nut, bolt and the wheel knuckle. ^ Discard the nut. ^ To install, tighten to 400 Nm (295 ft. lbs.). 7. If necessary, using a suitable press and adapters, remove the wheel knuckle bushing. 8. To install, reverse the removal procedure. 9. Check and, if necessary, adjust the rear alignment. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 8109 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 8110 Power Steering Fluid: Specifications POWER STEERING FLUID Motorcraft MERCON ATF Ford P/N .............................................................................................................................................. ............................................................ XT-2-QDX Ford Specification ................................................. ............................................................................................................................................ MERCON Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair Power Steering Fluid Cooler: Service and Repair Power Steering Fluid Cooler Material Removal and Installation CAUTION: While repairing the power steering system, care should be taken to prevent the entry of contaminants or premature failure of the power steering components can result. All vehicles 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 LH rear quarter trim panel. 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. Turn the air suspension switch to the OFF position, if equipped. 2. With the vehicle in NEUTRAL, position it on a hoist. Navigator vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Page 8114 3. Remove the pushpins and the deflector shield. All vehicles 4. Release the 2 clamps and disconnect the power steering fluid cooler hoses. 5. Remove the 2 bolts and remove the power steering fluid cooler. ^ To install, tighten to 11 Nm (8 ft. lbs.). 6. To install, reverse the removal procedure. Fill the power steering system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair Power Steering Fluid Reservoir: Service and Repair Power Steering Fluid Reservoir Material Removal and Installation CAUTION: While repairing the power steering system, care should be taken to prevent the entry of contaminants or premature failure of the power steering components can result. 1. Using a suitable suction device, remove the power steering fluid from the fluid reservoir. 2. Disconnect the supply hose from the fluid reservoir. 3. Disconnect the return hose from the fluid reservoir. 4. Remove the fluid reservoir bolt and the fluid reservoir. ^ To install, tighten to 11 Nm (8 ft. lbs.). 5. To install, reverse the removal procedure. ^ Fill the power steering system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line Power Steering Line/Hose: Service and Repair Power Steering Pump to Steering Gear Pressure Line Power Steering Pump to Steering Gear Pressure Line - 4x4 Materials Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line > Page 8122 Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line > Page 8123 Part 2 Removal and Installation CAUTION: While repairing the power steering system, care should be taken to prevent the entry of contaminants or premature failure of the power steering components can result. NOTE: New O-ring seals must be installed any time the lines are disconnected from the steering gear. All vehicles 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 LH quarter trim panel rear. 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. Failure to follow these instructions may result in personal injury. Turn the air suspension switch to the OFF position, if equipped. 2. With the vehicle in NEUTRAL, position it on a hoist. 3. Remove the engine cooling fan. 4. Remove the power steering pump pulley. 5. Disconnect the power steering pressure line-to-pump fitting. Discard the Teflon seal. ^ To install, tighten to 65 Nm (48 ft. lbs.). 6. Remove the 2 bolts and the oil drip shield. ^ To install, tighten to 11 Nm (8 ft. lbs.). 7. Remove the power steering pressure line bracket-to-crossmember bolt. ^ To install, tighten to 11 Nm (8 ft. lbs.). 8. Disconnect the power steering pressure line from the frame rail retainers. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line > Page 8124 9. Remove the power steering pressure line bracket-to-engine nut. ^ To install, tighten to 40 Nm (30 ft. lbs.). Expedition vehicles 10. If equipped disconnect the power steering pressure sensor electrical connector and detach the harness retainer. All vehicles CAUTION: New O-ring seals must be installed any time the lines are disconnected from the steering gear. 11. Remove the power steering line clamp plate bolt and the power steering pressure line. Discard the O-ring seal. 1 To install, tighten to 23 Nm (17 ft. lbs.). 12. To install, reverse the removal procedure. ^ Using the special tool, install a new Teflon O-ring seal on the power steering pressure line-to-pump fitting. ^ Install a new O-ring seal on the clamp plate end of the power steering pressure line. ^ Fill the power steering system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line > Page 8125 Power Steering Line/Hose: Service and Repair Power Steering Fluid Cooler to Power Steering Fluid Reservoir Return Hose Power Steering Fluid Cooler to Power Steering Fluid Reservoir Return Hose Material Removal and Installation CAUTION: While repairing the power steering system, care should be taken to prevent the entry of contaminants or premature failure of the power steering components can result. All vehicles 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 near in the LH rear quarter trim panel. 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. Failure to follow these instructions may result in personal injury. Turn the air suspension switch to the OFF position, if equipped. 2. With the vehicle in NEUTRAL, position it on a hoist. 3. Using a suitable suction device, remove the power steering fluid from the reservoir. 4. Remove the 3 power steering reservoir bolts. ^ To install, tighten to 11 Nm (8 ft. lbs.). 5. Release the clamp, and disconnect power steering return line from the reservoir. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line > Page 8126 Navigator vehicles 6. Remove the pushpins and the deflector shield. All vehicles 7. Release the clamp and disconnect the power steering return line from the power steering cooler. 8. Disconnect the power steering return line from the frame rail retainer and remove the line. 9. To install, reverse the removal procedure. Fill the power steering system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line > Page 8127 Power Steering Line/Hose: Service and Repair Steering Gear to Fluid Cooler Return Hose Steering Gear to Fluid Cooler Return Hose Materials Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line > Page 8128 Part 2 Removal and Installation CAUTION: While repairing the power steering system, care should be taken to prevent the entry of contaminants or premature failure of the power steering components can result. NOTE: New O-ring seals must be installed any time the lines are disconnected from the steering gear. All vehicles 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 LH rear quarter trim panel. 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. Turn the air suspension switch to the OFF position, if equipped. 2. With the vehicle in NEUTRAL, position it on a hoist. Navigator vehicles 3. Remove the pushpins and the deflector shield. All vehicles 4. Release the clamp and disconnect the power steering return line from the power steering cooler. 5. Remove the 2 bolts and the oil drip shield. ^ To install, tighten to 11 Nm (8 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Pump to Steering Gear Pressure Line > Page 8129 CAUTION: New O-ring seals must be installed any time the lines are disconnected from the steering gear. 6. Remove the steering line clamp plate bolt. ^ To install, tighten to 28 Nm (18 ft. lbs.). ^ Discard the steering line O-ring seals. 7. Disconnect the line from frame rail retainers and remove the return line. 8. To install, reverse the removal procedure. ^ Install a new O-ring seals. ^ Fill the power steering system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Locations View 151-35 (Chassis, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Locations > Page 8133 C120 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Power Steering Pump: Service and Repair Power Steering Pump Power Steering Pump Special Tools Material Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 8138 Removal and Installation CAUTION: While repairing the power steering system, care should be taken to prevent the entry of contaminants or premature failure of the power steering components can result. 1. Remove the engine cooling fan. 2. Remove the power steering pump pulley. 3. Release the clamp and disconnect the supply hose from power steering pump. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 8139 4. Remove the pressure line bracket-to-engine nut. ^ To install, tighten to 40 Nm (30 ft. lbs.). 5. Disconnect the pressure line-to-pump fitting. ^ Discard the Teflon O-ring seal. ^ To install, tighten to 65 Nm (48 ft. lbs.). 6. Remove the 3 pump bolts. ^ To install, tighten to 25 Nm (18 ft. lbs.). ^ Disconnect the harness retainer and remove the power steering pump. 7. To install, reverse the removal procedure. ^ Using the special tool, install a new Teflon O-ring on the pressure line-to-pump fitting. ^ Fill the power steering system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 8140 Power Steering Pump: Service and Repair Power Steering Pump Pulley Power Steering Pump Pulley Special Tools Removal Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 8141 1. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt from the power steering pump pulley. 2. Remove the air cleaner intake pipe. 3. Using the special tool, remove the power steering pump pulley. Installation 1. CAUTION: If the pulley has been removed and installed twice, install a new power steering pump pulley. Using the special tool, install the power steering pump pulley. ^ Inspect the pulley for paint marks in the web area near the hub. If there are 2 paint marks, install a new pulley. If there is 1 paint mark or none at all, use a paint pencil to mark the web area of the pulley near the hub. 2. Install the air cleaner intake pipe. 3. Rotate the accessory drive belt tensioner clockwise and install the accessory drive belt to the power steering pump pulley. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch POWER STEERING PRESSURE (PSP) SWITCH Typical Power Steering Pressure (PSP) Switch The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch > Page 8147 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor POWER STEERING PRESSURE (PSP) SENSOR Typical Power Steering Pressure (PSP) Sensor The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM changes as the hydraulic pressure changes. The PCM uses the input signal from the PSP sensor to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP sensor signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations View 151-14 (Steering Column) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 8151 C226 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Locations View 151-14 (Steering Column) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Locations > Page 8155 C226 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Depowering and Repowering SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING Depowering Procedure WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the electrical connector on a safety canopy module. Doing so can result in safety canopy deployment. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the RH side of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse 19 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located at the bottom of the hood latch support bracket. The first row side impact sensors (if equipped) are located in the first row doors, behind the door trim panel. The second row side impact sensors (if equipped) are located at or near the base of the C-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install the RCM fuse 19 (10A) to the CJB and close the cover. 4. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8161 Connect the battery ground cable. 5. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a diagnostic tool. Deactivation and Reactivation SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION Special Tool(s) Special Tool(s) Deactivation WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the connectors on the safety canopy module. Doing so can result in safety canopy module deployment. - To reduce the risk of personal injury, do not use any memory saver devices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8162 NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the RH side of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse 19 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located at the bottom of the hood latch support bracket. The first row side impact sensors (if equipped) are located in the first row doors, behind the door trim panel. The second row side impact sensors (if equipped) are located at or near the base of the C-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 7. Remove the 2 steering wheel back cover plugs (1 shown). 8. Remove the 2 driver air bag module bolts (1 shown). Expedition Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8163 9. Remove the driver air bag module. 1 Release the 2 retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector before disconnecting. 2 Release the 2 retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector before disconnecting. 3 Disconnect the horn switch electrical connector. 4 Remove the driver air bag module. Navigator 10. Disconnect the driver air bag module. - Release the 2 tabs on each driver air bag module electrical connector and disconnect them. Label each driver air bag module electrical connector before disconnecting. 11. Release the tab and disconnect the driver air bag module accessories electrical connector at the top of the clockspring and remove the driver air bag module. All vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8164 12. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of the steering column. 13. While pushing in on the 2 glove compartment door tabs, position the glove compartment downward. 14. NOTE: Expedition shown, Navigator similar. Through the glove compartment opening, release the tab and disconnect the passenger air bag module electrical connector. 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Vehicles with safety canopies Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8165 16. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or if it does not remain closed, install a new shoulder safety belt guide cover. Remove the second row passenger side safety belt guide. 1 Release the retaining tab at each side and open the safety belt guide cover. 2 Remove the nut. 3 Remove the second row passenger side safety belt guide. 17. Remove the passenger side C-pillar trim panel. 1 Separate the weather-stripping along the passenger side C-pillar trim panel. 2 Remove the bolt cover and bolt. 3 Pull out to release the retainers and remove the passenger side C-pillar trim panel. 18. Disconnect the passenger side safety canopy electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8166 19. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy electrical connector. 20. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or if it does not remain closed, install a new shoulder safety belt guide cover. Remove the second row driver side safety belt guide. 1 Release the retaining tab at each side and open the safety belt guide cover. 2 Remove the nut. 3 Remove the second row driver side safety belt guide. 21. Remove the driver side C-pillar trim panel. 1 Separate the weather-stripping along the driver side C-pillar trim panel. 2 Remove the bolt cover and bolt. 3 Pull out to release the retainers and remove the driver side C-pillar trim panel. 22. Disconnect the driver side safety canopy electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8167 23. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy electrical connector. All vehicles 24. Install the RCM fuse 19 (10A) to the CJB. 25. Connect the battery ground cable. Reactivation All vehicles 1. Remove the RCM fuse 19 (10A) from the CJB. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles with safety canopies 3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy electrical connector. 4. Connect the driver side safety canopy electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8168 5. WARNING: Anytime the safety canopy module has deployed, the headliner, and all A, B, and C pillar upper trim panels and attaching hardware must be replaced along with any other damaged components and hardware. Failure to do so may result in personal injury in the event of a safety canopy module deployment. Install the driver side C-pillar trim panel. 1 Position the driver side C-pillar trim panel and push in, engaging the retainers. 2 Install the bolt and bolt cover. Tighten to 11 Nm (8 lb-ft). 3 Install the weather-stripping along the driver side C-pillar trim panel. 6. NOTE: - Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or if it does not remain closed, install a new shoulder safety belt guide cover. - Make sure the safety belt is not twisted prior to installation. Install the second row driver side safety belt guide. 1 Position the second row driver side safety belt guide. 2 Install the nut. Tighten to 40 Nm (30 lb-ft). 3 Close the safety belt guide cover. Verify the safety belt retractor operates without excessive effort or binding. 7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8169 8. Connect the passenger side safety canopy electrical connector. 9. WARNING: Anytime the safety canopy module has deployed, the headliner, and all A, B, and C pillar upper trim panels and attaching hardware must be replaced along with any other damaged components and hardware. Failure to do so may result in personal injury in the event of a safety canopy module deployment. Install the passenger C-pillar trim panel. 1 Position the passenger side C-pillar trim panel and push in, engaging the retainers. 2 Install the bolt and bolt cover. Tighten to 11 Nm (8 lb-ft). 3 Install the weather-stripping along the passenger side C-pillar trim panel. 10. NOTE: - Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or if it does not remain closed, install a new shoulder safety belt guide cover. - Make sure the safety belt is not twisted prior to installation. Install the second row passenger side safety belt guide. 1 Position the second row passenger side safety belt guide. 2 Install the nut. Tighten to 40 Nm (30 lb-ft). 3 Close the safety belt guide cover. Verify the safety belt retractor operates without excessive effort or binding. All vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8170 11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. 12. NOTE: Expedition shown, Navigator similar. Connect the passenger air bag module electrical connector. 13. Close the glove compartment. 14. Remove the restraint system diagnostic tools from the clockspring electrical connector at the top of the steering column. Navigator 15. Connect the driver air bag module accessories electrical connector to the connector end at the top of the clockspring. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8171 16. CAUTION: The clockspring electrical connectors are unique and cannot be reversed when connected to the driver air bag module. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Connect the driver air bag module electrical connectors as noted during removal. Position the driver air bag module to the steering wheel. Expedition 17. Position the driver air bag module to the steering wheel. 1 Connect the horn switch electrical connector. 2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when connected to the driver air bag module. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Connect the driver air bag module electrical connectors as noted during removal. 3 Position the driver air bag module to the steering wheel. All vehicles 18. Install the 2 driver air bag module bolts (1 shown). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8172 19. Install the 2 steering wheel back cover plugs (1 shown). 20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse 19 (10A) to the CJB and close the cover. 23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a diagnostic tool. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8173 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure PROVE OUT PROCEDURE Turn the ignition switch from the OFF to the ON position and visually monitor the air bag indicator with all SRS components connected or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an SRS fault is present, the air bag indicator will: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair Steering Gear: Service and Repair Steering Gear Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Page 8177 Part 2 Removal and Installation CAUTION: While repairing the power steering system, care should be taken to prevent the entry of contaminants or premature failure of the power steering components can result. NOTE: New O-ring seals must be installed any time the lines are disconnected from the steering gear. All vehicles 1. With the vehicle in NEUTRAL, position the vehicle on a hoist. 2. CAUTION: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring can occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. Hold the steering wheel in the straight-ahead position using a suitable holding device. 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 LH rear quarter trim panel. 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. Turn the air suspension switch to the OFF position, if equipped. 4. Remove the engine cooling fan. 5. NOTE: Use the hex holding feature to prevent turning of the stud while removing the nut. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Page 8178 Remove the 2 nuts and disconnect the tie-rod ends from the wheel knuckles. ^ To install, tighten to 150 Nm (111 ft. lbs.). 6. Remove the 2 bolts and the oil drip shield. ^ To install, tighten to 10 Nm (89 inch lbs.). 7. Disconnect the lines from the frame rail retainers. 8. CAUTION: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring can occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. Remove the intermediate shaft-to-gear pinch bolt and disconnect the intermediate shaft from the gear. ^ To install, tighten to 30 Nm (22 ft. lbs.). 9. Remove the steering line clamp plate bolt and disconnect the power steering lines. ^ Position the lines aside. ^ Discard the O-ring seals. 1 To install, tighten to 23 Nm (17 ft. lbs.). Navigator vehicles 10. Disconnect the electrical connector. ^ Rotate the actuator until the connector housing is facing the steering gear input shaft. 11. Remove the left side lower arm-to-frame nut and bolt. Discard the nut. ^ To install, tighten to 200 Nm (148 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Page 8179 12. Insert a block of wood between the left side lower arm and the frame. All vehicles 13. Remove the 2 steering gear bracket-to-crossmember nuts and bolts. Discard the nuts. ^ To install, tighten to 103 Nm (76 ft. lbs.). 14. CAUTION: Make sure the steering lines are clear from the removal path of the gear or damage to the lines can result. Remove the 2 steering gear bracket-to-gear nuts, bolts, and brackets. Discard the nuts. ^ To install, tighten to 150 Nm (111 ft. lbs.). 15. Remove the steering gear from the left side of the vehicle. 16. CAUTION: Make sure that the wheel end vacuum line is clear of the steering gear mounting fasteners before tightening the bolts or damage to the line can result. CAUTION: Make sure to tighten the bracket-to-steering gear bolts (M14) before tightening the bracket-to crossmember bolts (M12) or damage to the steering gear can result. To install, reverse the removal procedure. ^ Install a new high pressure line O-ring seal and a new return line O-ring seal. ^ Fill and leak check the system. ^ Check and, if necessary, align the front end. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair Steering Shaft: Service and Repair Steering Column Shaft Steering Column Shaft Removal and Installation All vehicles 1. CAUTION: Do not allow the steering column shaft to rotate while the intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence that the shaft has rotated, the clockspring must be removed and recentered. Place the steering wheel in the straight-ahead position and turn the ignition switch to the OFF position. 2. NOTE: A new bolt must be installed. Remove the bolt and disconnect the intermediate shaft from the steering column. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Page 8183 ^ Discard the bolt. ^ To install, tighten to 30 Nm (22 ft. lbs.). 3. NOTE: A new bolt must be installed. Remove the bolt and disconnect the upper intermediate shaft from the lower intermediate shaft. ^ Discard the bolt. ^ To install, tighten to 48 Nm (35 ft. lbs.). 4. Remove the 2 bolts, the dash seal and the upper intermediate shaft. ^ To install, tighten to 12 Nm (9 ft. lbs.). Navigator 4x4 vehicles 5. Remove the cooling fan and shroud. All vehicles except Navigator 4x4 6. Raise and support the vehicle. 7. If equipped, remove the skid plate. ^ To install, tighten the front 2 bolts to 40 Nm (30 ft. lbs.). ^ To install, tighten the rear 2 bolts to 55 Nm (41 ft. lbs.). All vehicles 8. NOTE: A new bolt must be installed. Remove the bolt and the lower intermediate shaft. ^ Discard the bolt. ^ To install, tighten to 30 Nm (22 ft. lbs.). 9. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose Steering Wheel: Customer Interest Interior - Leather Wrapping On Steering Wheel Is Loose TSB 07-4-3 03/05/07 LEATHER - WRAPPED STEERING WHEEL - LEATHER COMING LOOSE FORD: 2000-2005 Thunderbird 2000-2007 Crown Victoria, Focus, Mustang, Taurus 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1999-2003 Windstar 1999-2008 F-Super Duty 2000-2005 Excursion 2000-2007 E-Series, Expedition, Explorer, Ranger 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2001-2008 Escape 2004-2007 F-150, Freestar 2005-2008 Escape Hybrid 2007 Edge 2004-2007 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 Lincoln LS 2000-2007 Town Car 2006 Zephyr 2007 MKZ 2000-2007 Navigator 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 2000-2005 Sable 2000-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 2000-2007 Mountaineer 2004-2007 Monterey 2005-2008 Mariner 2006-2008 Mariner Hybrid This article supersedes TSB 04-24-3 to update the vehicle model years. ISSUE Some vehicles equipped with leather-wrapped steering wheels may exhibit the leather coming loose from the spoke area. ACTION Apply Motorcraft Instant Gel Adhesive to re-adhere the loose leather to the wheel spoke. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF RE-ADHERING LEATHER TO THE FRONT SIDE OF THE STEERING WHEEL ONLY, OMIT STEPS 1 AND 6. STEERING WHEEL/AIR BAG ASSEMBLY REMOVAL IS NECESSARY ONLY WHEN REPAIRING LOOSE LEATHER ON THE BACKSIDE OF THE STEERING WHEEL. CAUTION AVOID SKIN CONTACT WITH MOTORCRAFT INSTANT GEL ADHESIVE. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose > Page 8192 1. Remove the steering wheel (ONLY NECESSARY TO REPAIR BACKSIDE OF STEERING WHEEL). Refer to Workshop Manual Sections 211-04 and 501-20B. 2. Fold loose leather out of the way. 3. Apply Motorcraft Instant Gel Adhesive evenly over the wheel spoke. 4. Fold the leather back into its original position. 5. Smooth the leather tuck in for neat appearance, and apply pressure until the leather is bonded to the wheel spoke (apply pressure for at least 30 seconds). NOTE THE ADHESIVE SHOULD BE COMPLETELY SET AFTER 5 MINUTES. DO NOT PULL ON THE REPAIR AREA. 6. Reinstall steering wheel. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT070403 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 3600 33 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose Steering Wheel: All Technical Service Bulletins Interior - Leather Wrapping On Steering Wheel Is Loose TSB 07-4-3 03/05/07 LEATHER - WRAPPED STEERING WHEEL - LEATHER COMING LOOSE FORD: 2000-2005 Thunderbird 2000-2007 Crown Victoria, Focus, Mustang, Taurus 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1999-2003 Windstar 1999-2008 F-Super Duty 2000-2005 Excursion 2000-2007 E-Series, Expedition, Explorer, Ranger 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2001-2008 Escape 2004-2007 F-150, Freestar 2005-2008 Escape Hybrid 2007 Edge 2004-2007 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 Lincoln LS 2000-2007 Town Car 2006 Zephyr 2007 MKZ 2000-2007 Navigator 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 2000-2005 Sable 2000-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 2000-2007 Mountaineer 2004-2007 Monterey 2005-2008 Mariner 2006-2008 Mariner Hybrid This article supersedes TSB 04-24-3 to update the vehicle model years. ISSUE Some vehicles equipped with leather-wrapped steering wheels may exhibit the leather coming loose from the spoke area. ACTION Apply Motorcraft Instant Gel Adhesive to re-adhere the loose leather to the wheel spoke. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF RE-ADHERING LEATHER TO THE FRONT SIDE OF THE STEERING WHEEL ONLY, OMIT STEPS 1 AND 6. STEERING WHEEL/AIR BAG ASSEMBLY REMOVAL IS NECESSARY ONLY WHEN REPAIRING LOOSE LEATHER ON THE BACKSIDE OF THE STEERING WHEEL. CAUTION AVOID SKIN CONTACT WITH MOTORCRAFT INSTANT GEL ADHESIVE. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose > Page 8198 1. Remove the steering wheel (ONLY NECESSARY TO REPAIR BACKSIDE OF STEERING WHEEL). Refer to Workshop Manual Sections 211-04 and 501-20B. 2. Fold loose leather out of the way. 3. Apply Motorcraft Instant Gel Adhesive evenly over the wheel spoke. 4. Fold the leather back into its original position. 5. Smooth the leather tuck in for neat appearance, and apply pressure until the leather is bonded to the wheel spoke (apply pressure for at least 30 seconds). NOTE THE ADHESIVE SHOULD BE COMPLETELY SET AFTER 5 MINUTES. DO NOT PULL ON THE REPAIR AREA. 6. Reinstall steering wheel. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT070403 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 3600 33 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 8199 Steering Wheel: Service and Repair STEERING WHEEL CONTROLS Removal and Installation All vehicles 1. Remove the driver air bag module. Expedition 2. Remove the 2 screws and the steering wheel controls. - Disconnect the electrical connector. Navigator 3. Remove the 4 switch plate bolts. - To install, tighten to 8 Nm (71 lb-in). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 8200 4. Remove the 2 steering wheel control screws and springs, and position the switch plate aside. 5. NOTE: Note the routing of the steering wheel controls harness on the module plate for installation of the new steering wheel controls. Disconnect the steering wheel controls harness from the clips, and remove the horn switch plate. All vehicles 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair Tie Rod: Service and Repair Inner Tie Rod Special Tools Materials Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Page 8204 Removal CAUTION: The boots and clamps are designed to provide an airtight seal and protect the internal components of the steering gear. If the seal is not airtight the vacuum generated during turning will draw water and contamination into the gear causing premature damage. CAUTION: Zip ties do not produce an airtight seal and must not be used. CAUTION: The inner ball joint grease is not compatible with water and contamination trapped in the grease will degrade the life of the joint. CAUTION: If present, the orientation of the vent tube must be noted so the boots and vent tubes can be installed in the correct location. 1. With the vehicle in NEUTRAL, position the vehicle on a hoist. 2. Loosen the tie-rod end jam nut. ^ Tighten to 103 Nm (76 ft. lbs.). 3. NOTE: The hex holding feature can be used to prevent turning of the stud while removing the tie-rod end nut. Remove the nut and disconnect the tie-rod end from the wheel knuckle. ^ To install, tighten to 150 Nm (111 ft. lbs.). 4. NOTE: Note the number of times the tie-rod ends turn for assembly reference. Remove the tie-rod end. 5. Remove the tie-rod end jam nut. 6. NOTE: If repairing the RH side, it will be necessary to pull back the LH inner tie rod bellows to hold the steering gear. Remove the inner and outer bellows boot clamps. 7. Remove the inner tie-rod bellows boot. 8. CAUTION: Place the steering gear at the center position. Use a 11/16 in. crowfoot on the flat of the rack gear to resist rotation and to prevent damage during removal and installation of the inner tie rod. NOTE: An assistant may be needed for removal of the RH inner tie rod. Using the special tool, remove the inner tie rod. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Page 8205 ^ To install, tighten to 100 Nm (74 ft. lbs.). 9. CAUTION: Thoroughly remove any abrasive material. This material is extremely harmful to the steering gear. Thoroughly clean and inspect all the parts to be reused. Install new parts as necessary. 10. Lubricate the inner tic rod and steering gear housing with specified grease. Grease should be applied at the groove, where the boot contacts and is clamped to the housing and tie rod. ^ Check that the inner tie-rod bellows boot is positioned correctly over the steering gear housing bead at the large inside diameter (ID) and is in the inner tie-rod groove at the small ID. ^ Check that the inner tie-rod bellows boot is not twisted and the breather tube is securely inserted into the breather nipple at both inner tie-rod bellows boots. 11. To install, reverse the removal procedure. 12. Check and, if necessary, align the front end. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications Ball Joint: Specifications Measure the ball joint deflection while an assistant pushes up and then pulls down on the upper control arm, by hand. ^ If the deflection exceeds the specification, a new ball joint must be installed. ^ If the deflection meets the specification, no further action is required. Wear limit ............................................................................................................................................. .......................................... 0-0.8 mm (0-0.032 in) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 8210 Ball Joint: Testing and Inspection Ball Joint Inspection 1. Prior to inspecting the ball joints for wear, inspect the wheel bearings. 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. 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. Failure to follow these instructions may result in personal injury. NOTE: In order to obtain accurate measurements, the suspension must be in full rebound with the weight of the vehicle supported by the frame. Raise and support the vehicle by the frame to allow the wheels to hang in the rebound position. 3. Inspect the ball joint and ball joint boot for damage. ^ If the ball joint or ball joint boot is damaged, install a new ball joint as necessary. NOTE: Carry out Steps 4-6 to inspect the lower ball joint. Carry out Steps 7-9 to inspect the upper ball joint. 4. CAUTION: Do not use any tools or equipment to move the wheel and tire assembly or suspension components while checking for relative movement. Suspension damage can occur. The use of tools or equipment will also create relative movement that may not exist when using hand force. Relative movement must be measured using hand force only. NOTE: The weight of the wheel and tire assembly must be overcome to obtain an accurate measurement on the dial indicator. Inspect the ball joint for relative movement by alternately pulling downward and pushing upward on the wheel and tire assembly by hand. Note any relative vertical movement between the wheel knuckle and lower arm at the lower ball joint. ^ If relative movement is not felt or seen, the ball joint is OK. Do not install a new ball joint. ^ If relative movement is found, continue with Step 5. 5. NOTE: In order to obtain an accurate measurement, the dial indicator should be aligned as close as possible with the vertical axis (center line) of the ball joint. To measure ball joint deflection, attach a suitable dial indicator with a flexible arm between the lower control arm and the wheel knuckle or ball joint stud. 6. Measure the ball joint deflection while an assistant pushes up and pulls down on the wheel and tire assembly, by hand. ^ If the deflection exceeds the specification, a new ball joint must be installed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 8211 ^ If the deflection meets the specification, continue with the procedure. 7. CAUTION: Do not use any tools or equipment to move the wheel and tire assembly or suspension components while checking for relative movement. Suspension damage can occur. The use of tools or equipment will also create relative movement that may not exist when using hand force. Relative movement must be measured using hand force only. ^ Inspect the ball Joint for relative movement by alternately pulling downward and pushing upward on the upper control arm by hand. Note any relative vertical movement between the wheel knuckle and upper arm at the upper ball joint. ^ If relative movement is not felt or seen, the ball Joint is OK. Do not install a new ball joint. ^ If relative movement is found, continue with Step 8. 8. NOTE: In order to obtain an accurate measurement, the dial indicator should be aligned as close as possible with the vertical axis of the ball joint. To measure ball joint deflection, attach a suitable dial indicator with a flexible arm between the upper control arm and the wheel knuckle or ball Joint stud. 9. Measure the ball joint deflection while an assistant pushes up and then pulls down on the upper control arm, by hand. ^ If the deflection exceeds the specification, a new ball joint must be installed. ^ If the deflection meets the specification, no further action is required. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 8212 Ball Joint: Service and Repair Ball Joint - Lower Special Tool(s) Special Tool(s) Material Material Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 8213 Removal 1. Remove the wheel knuckle. 2. Remove and discard the lower ball joint snap ring. 3. Using the special tools, remove the lower ball joint. Installation 1. Using a clean shop towel and the specified surface cleaner, clean the lower arm ball joint bore and inspect for cracks or damage before installing a new ball joint. If there is evidence of cracks or damage, a new lower arm must be installed. 2. CAUTION: Use care to prevent adhesive from contacting the ball joint boot or damage to the boot may occur, causing premature ball joint failure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 8214 NOTE: To allow the adhesive to fully cure, the vehicle must not be driven on the road for at least one hour after the installation of a new ball joint . Apply an even coat of adhesive (supplied with kit) to the lower arm ball joint bore and the ball joint. 3. CAUTION: Do not damage the lower ball joint boot when installing the special tool or premature failure of the ball joint may occur. NOTE: Make sure the ball joint snap ring is fully seated. Using the special tools, install the lower ball joint. Install the ball joint snap ring. 4. Using a clean shop towel and the specified surface cleaner, wipe any excess adhesive from the ball joint and lower arm. 5. Install the wheel knuckle. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Control Arm: Service and Repair Front Lower Arm Removal and Installation 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 LH rear quarter trim panel. 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. Failure to follow these instructions may result in personal injury. CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. If equipped, turn the air suspension switch to the OFF position. 2. Remove the wheel knuckle. 3. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut. Remove and discard the stabilizer bar link lower nut. ^ To install, tighten to 90 Nm (66 ft. lbs.). 4. Remove the lower arm rearward nut and bolt. ^ Discard the nut. ^ To install, tighten to 270 Nm (199 ft. lbs.). 5. Remove the lower arm forward nut and bolt. ^ Discard the nut. ^ To install, tighten to 270 Nm (199 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 8219 6. Remove the shock absorber lower nut, bolt and the lower arm. ^ Discard the shock absorber lower nut. ^ To install, tighten to 475 Nm (350 ft. lbs.). 7. CAUTION: Do not tighten the lower arm forward and rearward nuts and bolts until the installation procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies. To install, reverse the removal procedure. 8. Check and, if necessary, align the front end. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 8220 Control Arm: Service and Repair Rear Upper Arm Upper Arm Removal and Installation 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 LH rear quarter trim panel. 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. Failure to follow these instructions may result in personal injury. CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. If equipped, turn the air suspension switch to the OFF position. 2. With the vehicle in NEUTRAL, position it on a hoist. 3. Remove the parking brake cable wire form bracket bolt. ^ To install, tighten to 35 Nm (26 ft. lbs.). 4. Remove the upper arm-to-wheel knuckle nut and bolt. ^ Discard the nut. ^ To install, tighten to 150 Nm (111 ft. lbs.). 5. Remove the upper arm forward nut and bolt. ^ Discard the nut. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 8221 ^ To install, tighten to 150 Nm (111 ft. lbs.). 6. Remove the upper arm rearward nut, bolt and the upper arm. ^ Discard the nut. ^ To install, tighten to 250 Nm (184 ft. lbs.). 7. CAUTION: Do not tighten the upper arm forward and rearward nuts and bolts until the installation procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies. To install, reverse the removal procedure. 8. Check and, if necessary, adjust the rear alignment. Lower Arm Lower Arm Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 8222 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 8223 Removal and Installation 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 LH rear quarter trim panel. 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. Failure to follow these instructions may result in personal injury. CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. If equipped, turn the air suspension switch to the OFF position. 2. With the vehicle in NEUTRAL, position it on a hoist. 3. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut. Remove and discard the stabilizer bar link upper nut. ^ To install, tighten to 80 Nm (59 ft. lbs.). 4. Remove the shock absorber lower bolt and nut. ^ Discard the nut. ^ To install, tighten to 400 Nm (295 ft. lbs.). 5. Remove the lower arm forward nut and bolt. ^ Discard the nut. ^ To install, tighten to 250 Nm (184 ft. lbs.). 6. Remove the lower arm rear-ward nut and bolt. ^ Discard the nut. ^ To install, tighten to 250 Nm (184 ft. lbs.). 7. Remove the lower arm-to-wheel knuckle bolt, nut and the lower arm. ^ Discard the nut. ^ To install, tighten to 400 Nm (295 ft. lbs.). 8. If necessary, using a suitable press and adapters, remove the lower arm-to-wheel knuckle bushing. 9. CAUTION: Do not tighten the lower arm forward and rearward nuts and bolts until the installation procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies. To install, reverse the removal procedure. 10. Check and, if necessary, adjust the rear alignment. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Spot Welds - Rear Cross Member & Side Members Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Spot Welds - Rear Cross Member & Side Members > Page 8229 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Spot Welds - Rear Cross Member & Side Members > Page 8230 Rear Cross-Member: Service and Repair Transmission Support Crossmember TRANSMISSION SUPPORT CROSSMEMBER Transmission Support Crossmember - Exploded View Removal and Installation 1. Raise and support the vehicle. 2. If equipped, remove the skid plate fasteners and skid plate. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Spot Welds - Rear Cross Member & Side Members > Page 8231 3. Remove the LH and RH exhaust heat shield-to-crossmember fasteners. 4. Remove the 2 transmission mount nuts. - To install, tighten to 103 Nm (76 lb-ft). 5. Support the transmission. 6. NOTE: Mark the transmission crossmember next to the edge of the frame bracket to make sure the crossmember is installed in the same position it was removed from. Remove the 4 transmission crossmember bolts and transmission crossmember. To install, tighten to 90 Nm (66 lb-ft). 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Front Front Steering Knuckle: Service and Repair Front Wheel Knuckle Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Front > Page 8236 service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Remove the wheel hub. 2. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut. Remove the tie-rod end nut and detach the tie-rod end from the wheel knuckle. ^ Discard the nut. ^ To install, tighten to 150 Nm (111 ft. lbs.). 3. Remove the brake hose bracket bolt and position the brake hose aside. ^ To install, tighten to 12 Nm (9 ft. lbs.). 4. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut. Remove and discard the stabilizer bar link lower nut. ^ To install, tighten to 90 Nm (66 ft. lbs.). 5. Remove the shock absorber lower nut and bolt. ^ Discard the nut. ^ To install, tighten to 475 Nm (350 ft. lbs.). 6. Remove the 3 integrated wheel end disconnect bolts. ^ To install, tighten to 15 Nm (11 ft. lbs.). 7. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut. NOTE: To separate the ball joint from the wheel knuckle, loosely install the nut and then tap on the end of the stud. Remove the lower ball joint nut and separate the ball Joint from the knuckle. ^ Discard the nut. ^ To install, tighten to 200 Nm (148 ft. lbs.). 8. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut. Remove the upper ball Joint nut and the wheel knuckle. ^ Discard the nut. ^ To install, tighten to 150 Nm (111 ft. lbs.). 9. If necessary, remove the 3 brake disc shield bolts and remove the brake disc shield. ^ To install, tighten to 12 Nm (9 ft. lbs.). 10. To install, reverse the removal procedure. 11. Check and, if necessary, align the front end. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Front > Page 8237 Front Steering Knuckle: Service and Repair Rear Wheel Knuckle Removal and Installation 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 LH rear quarter trim panel. 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. Failure to follow these instructions may result in personal injury. CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Remove the wheel bearing and hub assembly. 2. Remove the parking brake shoe retaining clips, adjuster spring, return spring, adjuster and the parking brake shoes. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Front > Page 8238 3. Depress the tabs and detach the parking brake cable from the wheel knuckle. 4. Remove the toe link-to-wheel knuckle nut and detach the toe link from the wheel knuckle. ^ Discard the nut. ^ To install, tighten to 55 Nm (41 ft. lbs.). 5. Remove the upper arm-to-wheel knuckle nut and bolt. ^ Discard the nut. ^ To install, tighten to 150 Nm (111 ft. lbs.). 6. Remove the lower arm-to-wheel knuckle nut, bolt and the wheel knuckle. ^ Discard the nut. ^ To install, tighten to 400 Nm (295 ft. lbs.). 7. If necessary, using a suitable press and adapters, remove the wheel knuckle bushing. 8. To install, reverse the removal procedure. 9. Check and, if necessary, adjust the rear alignment. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle Alignment Link > Component Information > Service and Repair Rear Knuckle Alignment Link: Service and Repair Toe Link Removal and Installation 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 LH rear quarter trim panel. 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. Failure to follow these instructions may result in personal injury. CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. If equipped, turn the air suspension switch to the OFF position. 2. With the vehicle in NEUTRAL, position it on a hoist. 3. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut. Remove the toe link-to-wheel knuckle nut and separate the toe link from the wheel knuckle. ^ To install, tighten to 55 Nm (41 ft. lbs.). 4. Remove the toe link-to-frame nut and the toe link. ^ To install, tighten to 70 Nm (52 ft. lbs.). 5. To install, reverse the removal procedure. 6. Check and, if necessary, adjust the rear toe. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 8246 C1300 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 8247 Compressor/Pump Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 8248 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations Suspension Control Module: Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 8252 View 151-15 (LH A-Pillar) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 8253 Suspension Control Module: Diagrams C2131a C2131b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 8254 C2324a C2324b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 8255 Suspension Control Module: Service and Repair Air Suspension Control Module Removal and Installation 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable. 2. NOTE: The air suspension control module is mounted to the lower left side of the dash above the parking brake control. Disconnect the 2 air suspension control module electrical connectors. 3. Pull back the dash padding to expose the 2 module bracket nuts. 4. Remove the air suspension control module nuts and the air suspension control module. ^ To install, tighten to 8 Nm (71 inch lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 8256 5. NOTE: The air suspension control module is calibrated with information from the ride height sensors. A new or exchanged air suspension control module requires that the ride height adjustment calibration and pneumatic test be carried out. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins > Customer Interest for Ride Height Sensor: > 06-15-10 > Aug > 06 > Suspension - Air Suspension Height Sensor Linkage Loose Ride Height Sensor: Customer Interest Suspension - Air Suspension Height Sensor Linkage Loose TSB 06-15-10 08/07/06 AIR SUSPENSION PERFORMANCE - HEIGHT SENSOR LINKAGE ARM DISENGAGING FORD: 2003-2006 Expedition LINCOLN: 2003-2006 Navigator ISSUE Some 2003-2006 Expedition and Navigator vehicles equipped with an air suspension may exhibit an air suspension height sensor linkage arm disengaging from the suspension ball stud or height sensor rotating arm. This concern typically occurs with the rear sensor (Figure 1) but may occur with the front sensors as well. If this occurs, the symptom will typically be the vehicle leaning to one side, the vehicle sitting too low/high, a harsh ride, and/or an inoperative air suspension. In addition, this concern may result in diagnostic trouble code (DTC) C1725 (air suspension front pneumatic failure) or C1726 (air suspension rear pneumatic failure). ACTION When a linkage arm becomes disengaged, do not re-attach the arm and do not replace the sensor unless broken. Instead, install a revised linkage arm on all three (3) sensor assemblies, even if they have not detached from the ball stud. Refer to the following Service Procedure. SERVICE PROCEDURE Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins > Customer Interest for Ride Height Sensor: > 06-15-10 > Aug > 06 > Suspension - Air Suspension Height Sensor Linkage Loose > Page 8266 NOTE LINKAGE ARMS USED AS ORIGINAL EQUIPMENT ARE SHOWN IN FIGURE 2. REVISED LINKAGE ARMS (FIGURE 3) HAVE A NEW DESIGN THAT MAKES IT MORE DIFFICULT TO DISENGAGE FROM THE BALL STUDS. NOTE IF THE SENSOR ASSEMBLY NEEDS TO BE REPLACED FOR ANY DAMAGE/FAILURE OTHER THAN THE ONE DESCRIBED IN THIS TSB, THE REPLACEMENT ASSEMBLY IS SUPPLIED WITH A NEW STYLE LINKAGE ARM, SO THERE IS NO NEED TO ORDER ADDITIONAL LINKAGES FOR THE SERVICE REPAIR. 1. Replace linkage arms on all three (3) sensor assemblies following Workshop Manual (WSM), Section 204-05. 2. Discard the old linkage arms. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061510A 2003-2006 0.4 Hr. Expedition/Navigator: Replace The Three Linkage Arms, Includes Time To Check Diagnostic Trouble Codes (Do Not Use With 5300A, 5300A7, 5300A8) DEALER CODING CONDITION BASIC PART NO. CODE 5A967 07 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ride Height Sensor: > 06-15-10 > Aug > 06 > Suspension - Air Suspension Height Sensor Linkage Loose Ride Height Sensor: All Technical Service Bulletins Suspension - Air Suspension Height Sensor Linkage Loose TSB 06-15-10 08/07/06 AIR SUSPENSION PERFORMANCE - HEIGHT SENSOR LINKAGE ARM DISENGAGING FORD: 2003-2006 Expedition LINCOLN: 2003-2006 Navigator ISSUE Some 2003-2006 Expedition and Navigator vehicles equipped with an air suspension may exhibit an air suspension height sensor linkage arm disengaging from the suspension ball stud or height sensor rotating arm. This concern typically occurs with the rear sensor (Figure 1) but may occur with the front sensors as well. If this occurs, the symptom will typically be the vehicle leaning to one side, the vehicle sitting too low/high, a harsh ride, and/or an inoperative air suspension. In addition, this concern may result in diagnostic trouble code (DTC) C1725 (air suspension front pneumatic failure) or C1726 (air suspension rear pneumatic failure). ACTION When a linkage arm becomes disengaged, do not re-attach the arm and do not replace the sensor unless broken. Instead, install a revised linkage arm on all three (3) sensor assemblies, even if they have not detached from the ball stud. Refer to the following Service Procedure. SERVICE PROCEDURE Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ride Height Sensor: > 06-15-10 > Aug > 06 > Suspension - Air Suspension Height Sensor Linkage Loose > Page 8272 NOTE LINKAGE ARMS USED AS ORIGINAL EQUIPMENT ARE SHOWN IN FIGURE 2. REVISED LINKAGE ARMS (FIGURE 3) HAVE A NEW DESIGN THAT MAKES IT MORE DIFFICULT TO DISENGAGE FROM THE BALL STUDS. NOTE IF THE SENSOR ASSEMBLY NEEDS TO BE REPLACED FOR ANY DAMAGE/FAILURE OTHER THAN THE ONE DESCRIBED IN THIS TSB, THE REPLACEMENT ASSEMBLY IS SUPPLIED WITH A NEW STYLE LINKAGE ARM, SO THERE IS NO NEED TO ORDER ADDITIONAL LINKAGES FOR THE SERVICE REPAIR. 1. Replace linkage arms on all three (3) sensor assemblies following Workshop Manual (WSM), Section 204-05. 2. Discard the old linkage arms. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061510A 2003-2006 0.4 Hr. Expedition/Navigator: Replace The Three Linkage Arms, Includes Time To Check Diagnostic Trouble Codes (Do Not Use With 5300A, 5300A7, 5300A8) DEALER CODING CONDITION BASIC PART NO. CODE 5A967 07 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins > Page 8273 Ride Height Sensor: Service and Repair Suspension Height Sensor Front Height Sensor Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins > Page 8274 Rear Height Sensor Removal and Installation 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 LH quarter trim panel. 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. All sensors 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the sensor arm from the vehicle. Front sensor 3. Remove and discard the 2 sensor nuts. ^ To install, tighten to 30 Nm (22 ft. lbs.). Rear sensor 4. Remove and discard the sensor nuts and bolts. ^ To install, tighten to 15 Nm (13 ft. lbs.). All sensors 5. Disconnect the sensor electrical connector. 6. NOTE: The RH and LH height sensors cannot be used on opposite sides of the vehicle. To install, reverse the removal procedure. 7. Calibrate the height sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations View 151-14 (Steering Column) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 8278 C226 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Locations View 151-19 (Left Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Locations > Page 8282 C4169 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair Stabilizer Link: Service and Repair Stabilizer Bar and Link Removal and Installation 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 LH rear quarter trim panel. 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. Failure to follow these instructions may result in personal injury. CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. If equipped, turn the air suspension switch to the OFF position. 2. With the vehicle in NEUTRAL, position it on a hoist. 3. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut. Remove the 2 stabilizer bar link upper nuts. ^ Discard the nuts. ^ To install, tighten to 80 Nm (59 ft. lbs.). 4. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut. Remove the 2 stabilizer bar link lower nuts and the 2 stabilizer bar links. ^ Discard the nuts. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Page 8287 ^ To install, tighten to 80 Nm (59 ft. lbs.). 5. Remove the 4 stabilizer bar bracket nuts, the 2 stabilizer bar brackets and the stabilizer bar. ^ To install, tighten to 55 Nm (41 ft. lbs.). 6. NOTE: Inspect and, if necessary, install new bushings. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Service and Repair Air Dryer: Service and Repair Air Suspension Compressor Drier Removal and Installation 1. Remove the air compressor. 2. Remove the compressor drier screw. ^ To install, tighten to 3 Nm (27 inch lbs.). 3. NOTE: Make sure that the drier O-ring does not remain inside of the compressor assembly. Rotate the compressor drier 90 degrees counterclockwise to unlock, then remove the air compressor drier. 4. NOTE: Inspect the compressor drier O-ring for damage and install a new O-ring as necessary. NOTE: When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Service and Repair Air Line: Service and Repair Air Line Repair 1. Cut the line at the damaged area. 2. Trim the sleeve material from both ends of the damaged line. 3. Taper both ends of the tube by shaving or sanding it 3 mm (0.11 inch) from the tips. 4. Install the repair filling. 5. NOTE: Check system for leaks. Inflate the air suspension system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Air Shock Absorber - Front Air Spring: Service and Repair Air Shock Absorber - Front Air Shock Absorber - Front Special Tools Materials Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Air Shock Absorber - Front > Page 8299 Removal and Installation 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 LH rear quarter trim panel. 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. 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. Failure to follow these instructions may Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Air Shock Absorber - Front > Page 8300 result in personal injury. CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number must be used if installation is necessary. Do not use a new part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Using the diagnostic too], vent the appropriate air spring(s). 2. Turn the air suspension switch to the OFF position. 3. Remove and discard the 3 shock upper nuts. ^ To install, tighten to 40 Nm (30 ft. lbs.). 4. With the vehicle in NEUTRAL, position it on a hoist. 5. Disconnect the air valve electrical connector. 6. Disconnect the air line at the air valve. ^ Compress the orange quick connect lock ring, then pull downward on the air supply line. 7. Remove the shock lower nut, bolt and the air shock absorber and spring assembly. ^ Discard the nut. ^ To install, tighten to 400 Nm (295 ft. lbs.). 8. NOTE: If the individual spring and/or shock components are not being serviced, continue with Step 14. NOTE: Use the hex holding feature to prevent the shock rod from turning while removing the nut. Remove and discard the shock rod nut. ^ To install, tighten to 30 Nm (22 ft. lbs.). 9. CAUTION: If the retainer tabs are broken, a new air spring must be installed. NOTE: Index mark the air spring and the shock absorber for reference during the installation procedure. Depress the retainer tabs and remove the air spring assembly. 10. Remove the shock rod O-ring seal, washer and jounce bumper. ^ Discard the seal and washer. 11. Remove and discard the 2 air spring lower O-ring seals. 12. Remove the retainer pins and the upper mount. ^ Discard the pins. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Air Shock Absorber - Front > Page 8301 13. Remove and discard the 2 air spring upper O-ring seals. 14. CAUTION: Use a suitable press to install the upper mount retainer pins. Do not use a hammer or damage may occur. NOTE: During installation, use assembly kit 5B302. NOTE: Apply a thin coat of grease to the new O-ring seals. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Air Shock Absorber - Front > Page 8302 Air Spring: Service and Repair Air Shock Absorber - Rear Air Shock Absorber - Rear Special Tools Material Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Air Shock Absorber - Front > Page 8303 Removal and Installation 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 LH quarter trim panel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Air Shock Absorber - Front > Page 8304 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. 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. Failure to follow these instructions may result in personal injury. CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number must be used if installation is necessary. Do not use a new part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Using the diagnostic tool, vent the appropriate air spring. 2. Turn the air suspension switch to the OFF position. 3. With the vehicle in NEUTRAL, position it on a hoist. 4. Remove and discard the 3 shock upper nuts. ^ To install, tighten to 40 Nm (30 ft. lbs.). 5. Disconnect the air valve electrical connector. 6. Disconnect the air line at the air valve. Compress the orange quick connect lock ring, then pull downward on the air supply line. 7. Remove the shock absorber lower nut and bolt ^ Discard the nut. ^ To install, tighten to 475 Nm (350 ft. lbs.). 8. Remove the air shock absorber. 9. NOTE: If the individual spring and/or shock components are not being serviced, continue with Step 15. NOTE: Use the hex holding feature to prevent the shock rod from turning while removing the nut. Remove and discard the shock rod nut. To install, tighten to 30 Nm (22 ft. lbs.). 10. CAUTION: If the retainer tabs are broken, a new air spring must be installed. NOTE: Index mark the air spring and shock absorber for reference during the installation procedure. Depress the retainer tabs and remove the air spring. 11. Remove the shock rod O-ring seal, washer and jounce bumper. ^ Discard the seal and washer. 12. Remove and discard the 2 air spring lower O-ring seals. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Air Shock Absorber - Front > Page 8305 13. Remove the retainer pins and the upper mount. ^ Discard the pins. 14. Remove and discard the 2 air spring upper O-ring seals. 15. CAUTION: Use a suitable press to install the upper mount retainer pins. Do not use a hammer or damage may occur. NOTE: During installation, use assembly kit 5L74-5B302-AA NOTE: Apply a thin coat of grease to the new O-ring seals. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Air Suspension Compressor Assembly C1179 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Air Suspension Compressor Assembly > Page 8310 C1300 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Page 8311 Compressor/Pump: Service and Repair Air Suspension Compressor Removal and Installation 1. Remove the air suspension relay from the bracket. 2. Remove the windshield washer pump and reservoir. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Diagrams > Page 8312 3. Disconnect the air line from the compressor drier. Compress the orange quick connect lock ring inward, then pull the line outward from the air drier. 4. Disconnect the air compressor electrical connector. 5. Remove the air compressor bracket bolts and remove the air compressor/drier assembly. ^ To install, tighten to 9 Nm (80 inch lbs.). 6. If the bracket will be discarded, remove the bracket from the air compressor. 1 Remove and discard the 3 screws and washers. 2 Remove and discard the 3 rubber isolators from the air compressor. 3 Remove and discard the silencer (muffler) retaining screws and remove the silencer from the bracket. 7. 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. NOTE: Make sure that there are no objects trapped under or on the bracket. Make sure that the air compressor is not in contact with any surrounding components that could cause vibration noises. NOTE: Make sure that the air compressor moves freely in the rubber isolators. Make sure that the bracket has no deformations that could cause the 3 rubber isolators to load against each other. If installing a new bracket from the kit, only use the new fasteners supplied as instructed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 8316 C1300 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 8317 Compressor/Pump Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 8318 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Damping Control Actuator > Component Information > Locations > Air Spring Solenoid Valve, Right/Left Front View 151-35 (Chassis, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Damping Control Actuator > Component Information > Locations > Air Spring Solenoid Valve, Right/Left Front > Page 8323 View 151-36 (Chassis, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Damping Control Actuator > Component Information > Diagrams > Air Spring Solenoid Valve, Left Front C1154 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Damping Control Actuator > Component Information > Diagrams > Air Spring Solenoid Valve, Left Front > Page 8326 C1155 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Damping Control Actuator > Component Information > Diagrams > Air Spring Solenoid Valve, Left Front > Page 8327 C4044 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Damping Control Actuator > Component Information > Diagrams > Air Spring Solenoid Valve, Left Front > Page 8328 C4045 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair Level Control Solenoid Valve: Service and Repair Air Spring Solenoid Valve Special Tools Materials Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Page 8332 Part 2 NOTE: Front shown rear similar. Removal and Installation 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 LH quarter trim panel. 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. 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. Failure to follow these instructions may result in personal injury. NOTE: Front shown, rear similar. 1. If the air spring solenoid valve is functional, use the diagnostic tool to vent the appropriate air spring(s). 2. Turn the air suspension switch to the OFF position. 3. With the vehicle in NEUTRAL, position it on a hoist. 4. Disconnect the air valve electrical connector. 5. Disconnect the air line at the air valve. ^ Compress the orange quick connect lock ring, then pull downward on the air supply line. 6. CAUTION: Remove any dirt or other foreign material from the air spring assembly prior to removing the air spring solenoid valve from the air spring assembly. Remove the air spring solenoid clip. 7. WARNING: The air spring solenoid valve has a 2 stage release. When removing a non-functional solenoid and the air spring is inflated, carefully rotate the solenoid counterclockwise until it reaches the first stage to release the air from the air spring. Turn the solenoid to the second stage to remove the solenoid. Failure to follow these instructions when removing a non-functional air spring solenoid may result in personal injury or damage to components as high pressure air is vented uncontrolled. Rotate the air spring solenoid and remove the solenoid. 8. NOTE: Inspect the air spring O-ring for damage and install a new O-ring as necessary. Lightly lubricate the solenoid sea] area with silicone grease. NOTE: After installing the solenoid, it is necessary to inflate the air suspension system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Page 8333 NOTE: When installing the air spring solenoid, make sure that the electrical connector is positioned away from the air spring. NOTE: When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins > Customer Interest for Ride Height Sensor: > 06-15-10 > Aug > 06 > Suspension - Air Suspension Height Sensor Linkage Loose Ride Height Sensor: Customer Interest Suspension - Air Suspension Height Sensor Linkage Loose TSB 06-15-10 08/07/06 AIR SUSPENSION PERFORMANCE - HEIGHT SENSOR LINKAGE ARM DISENGAGING FORD: 2003-2006 Expedition LINCOLN: 2003-2006 Navigator ISSUE Some 2003-2006 Expedition and Navigator vehicles equipped with an air suspension may exhibit an air suspension height sensor linkage arm disengaging from the suspension ball stud or height sensor rotating arm. This concern typically occurs with the rear sensor (Figure 1) but may occur with the front sensors as well. If this occurs, the symptom will typically be the vehicle leaning to one side, the vehicle sitting too low/high, a harsh ride, and/or an inoperative air suspension. In addition, this concern may result in diagnostic trouble code (DTC) C1725 (air suspension front pneumatic failure) or C1726 (air suspension rear pneumatic failure). ACTION When a linkage arm becomes disengaged, do not re-attach the arm and do not replace the sensor unless broken. Instead, install a revised linkage arm on all three (3) sensor assemblies, even if they have not detached from the ball stud. Refer to the following Service Procedure. SERVICE PROCEDURE Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins > Customer Interest for Ride Height Sensor: > 06-15-10 > Aug > 06 > Suspension - Air Suspension Height Sensor Linkage Loose > Page 8342 NOTE LINKAGE ARMS USED AS ORIGINAL EQUIPMENT ARE SHOWN IN FIGURE 2. REVISED LINKAGE ARMS (FIGURE 3) HAVE A NEW DESIGN THAT MAKES IT MORE DIFFICULT TO DISENGAGE FROM THE BALL STUDS. NOTE IF THE SENSOR ASSEMBLY NEEDS TO BE REPLACED FOR ANY DAMAGE/FAILURE OTHER THAN THE ONE DESCRIBED IN THIS TSB, THE REPLACEMENT ASSEMBLY IS SUPPLIED WITH A NEW STYLE LINKAGE ARM, SO THERE IS NO NEED TO ORDER ADDITIONAL LINKAGES FOR THE SERVICE REPAIR. 1. Replace linkage arms on all three (3) sensor assemblies following Workshop Manual (WSM), Section 204-05. 2. Discard the old linkage arms. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061510A 2003-2006 0.4 Hr. Expedition/Navigator: Replace The Three Linkage Arms, Includes Time To Check Diagnostic Trouble Codes (Do Not Use With 5300A, 5300A7, 5300A8) DEALER CODING CONDITION BASIC PART NO. CODE 5A967 07 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ride Height Sensor: > 06-15-10 > Aug > 06 > Suspension - Air Suspension Height Sensor Linkage Loose Ride Height Sensor: All Technical Service Bulletins Suspension - Air Suspension Height Sensor Linkage Loose TSB 06-15-10 08/07/06 AIR SUSPENSION PERFORMANCE - HEIGHT SENSOR LINKAGE ARM DISENGAGING FORD: 2003-2006 Expedition LINCOLN: 2003-2006 Navigator ISSUE Some 2003-2006 Expedition and Navigator vehicles equipped with an air suspension may exhibit an air suspension height sensor linkage arm disengaging from the suspension ball stud or height sensor rotating arm. This concern typically occurs with the rear sensor (Figure 1) but may occur with the front sensors as well. If this occurs, the symptom will typically be the vehicle leaning to one side, the vehicle sitting too low/high, a harsh ride, and/or an inoperative air suspension. In addition, this concern may result in diagnostic trouble code (DTC) C1725 (air suspension front pneumatic failure) or C1726 (air suspension rear pneumatic failure). ACTION When a linkage arm becomes disengaged, do not re-attach the arm and do not replace the sensor unless broken. Instead, install a revised linkage arm on all three (3) sensor assemblies, even if they have not detached from the ball stud. Refer to the following Service Procedure. SERVICE PROCEDURE Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ride Height Sensor: > 06-15-10 > Aug > 06 > Suspension - Air Suspension Height Sensor Linkage Loose > Page 8348 NOTE LINKAGE ARMS USED AS ORIGINAL EQUIPMENT ARE SHOWN IN FIGURE 2. REVISED LINKAGE ARMS (FIGURE 3) HAVE A NEW DESIGN THAT MAKES IT MORE DIFFICULT TO DISENGAGE FROM THE BALL STUDS. NOTE IF THE SENSOR ASSEMBLY NEEDS TO BE REPLACED FOR ANY DAMAGE/FAILURE OTHER THAN THE ONE DESCRIBED IN THIS TSB, THE REPLACEMENT ASSEMBLY IS SUPPLIED WITH A NEW STYLE LINKAGE ARM, SO THERE IS NO NEED TO ORDER ADDITIONAL LINKAGES FOR THE SERVICE REPAIR. 1. Replace linkage arms on all three (3) sensor assemblies following Workshop Manual (WSM), Section 204-05. 2. Discard the old linkage arms. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061510A 2003-2006 0.4 Hr. Expedition/Navigator: Replace The Three Linkage Arms, Includes Time To Check Diagnostic Trouble Codes (Do Not Use With 5300A, 5300A7, 5300A8) DEALER CODING CONDITION BASIC PART NO. CODE 5A967 07 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins > Page 8349 Ride Height Sensor: Service and Repair Suspension Height Sensor Front Height Sensor Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Technical Service Bulletins > Page 8350 Rear Height Sensor Removal and Installation 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 LH quarter trim panel. 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. All sensors 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the sensor arm from the vehicle. Front sensor 3. Remove and discard the 2 sensor nuts. ^ To install, tighten to 30 Nm (22 ft. lbs.). Rear sensor 4. Remove and discard the sensor nuts and bolts. ^ To install, tighten to 15 Nm (13 ft. lbs.). All sensors 5. Disconnect the sensor electrical connector. 6. NOTE: The RH and LH height sensors cannot be used on opposite sides of the vehicle. To install, reverse the removal procedure. 7. Calibrate the height sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Locations Suspension Control Module: Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Locations > Page 8354 View 151-15 (LH A-Pillar) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Locations > Page 8355 Suspension Control Module: Diagrams C2131a C2131b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Locations > Page 8356 C2324a C2324b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Locations > Page 8357 Suspension Control Module: Service and Repair Air Suspension Control Module Removal and Installation 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable. 2. NOTE: The air suspension control module is mounted to the lower left side of the dash above the parking brake control. Disconnect the 2 air suspension control module electrical connectors. 3. Pull back the dash padding to expose the 2 module bracket nuts. 4. Remove the air suspension control module nuts and the air suspension control module. ^ To install, tighten to 8 Nm (71 inch lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Locations > Page 8358 5. NOTE: The air suspension control module is calibrated with information from the ride height sensors. A new or exchanged air suspension control module requires that the ride height adjustment calibration and pneumatic test be carried out. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Mode Switch > Component Information > Locations View 151-19 (Left Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Mode Switch > Component Information > Locations > Page 8362 C4169 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair Suspension Spring ( Coil / Leaf ): Service and Repair Shock Absorber and Spring Assembly Removal and Installation 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 LH rear quarter trim panel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Page 8366 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. Failure to follow these instructions may result in personal injury. CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. If equipped, turn the air suspension switch to the OFF position. 2. With the vehicle in NEUTRAL, position it on a hoist. 3. Remove and discard the shock and spring assembly upper nuts. ^ To install, tighten to 35 Nm (26 ft. lbs.). 4. Remove the shock absorber lower nut and bolt. ^ Discard the nut. ^ To install, tighten to 400 Nm (295 ft. lbs.). 5. Remove the shock absorber and spring assembly. 6. NOTE: If the individual spring and/or shock components are not being serviced, continue with Step 9. NOTE: For reference during assembly, index the upper mount, spring and shock absorber. Using a suitable spring compressor, compress the spring until the tension is released from the shock absorber. 7. While holding the shock rod, remove the nut and washer. ^ Remove the shock absorber. ^ Discard the nut. ^ To install, tighten to 30 Nm (22 ft. lbs.). 8. Remove the upper mount, dust boot and insulator. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Page 8367 9. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Rear Suspension Strut / Shock Absorber: Service and Repair Rear Shock Absorber and Spring Assembly Removal and Installation WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Rear > Page 8372 This can be accomplished by turning off the air suspension switch located in the LH rear quarter trim panel. 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. Failure to follow these instructions may result in personal injury. CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. If equipped, turn the air suspension switch to the OFF position. 2. With the vehicle in NEUTRAL, position it on a hoist. 3. Remove and discard the shock and spring assembly upper nuts. ^ To install, tighten to 35 Nm (26 ft. lbs.). 4. Remove the shock absorber lower nut and bolt. ^ Discard the nut. ^ To install, tighten to 400 Nm (295 ft. lbs.). 5. Remove the shock absorber and spring assembly. 6. NOTE: If the individual spring and/or shock components are not being serviced, continue with Step 9. NOTE: For reference during assembly, index the upper mount, spring and shock absorber. Using a suitable spring compressor, compress the spring until the tension is released from the shock absorber. 7. While holding the shock rod, remove the nut and washer. ^ Remove the shock absorber. ^ Discard the nut. ^ To install, tighten to 30 Nm (22 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Rear > Page 8373 8. Remove the upper mount, dust boot and insulator. 9. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Rear > Page 8374 Suspension Strut / Shock Absorber: Service and Repair Shock Absorber "For information regarding this component please; refer to Air Spring service and repair" Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torque Rod > Component Information > Technical Service Bulletins > Customer Interest for Torque Rod: > 05-16-1 > Aug > 05 > A/T/Suspension - Clunk/Thump From Rear When Shifting A/T Torque Rod: Customer Interest A/T/Suspension - Clunk/Thump From Rear When Shifting A/T TSB 05-16-1 08/22/05 CLUNK/GRIND/THUMP NOISE FROM REAR OF VEHICLE WHEN TRANSMISSION IS SHIFTED - VEHICLES BUILT BEFORE 6/13/2005 FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator ISSUE Some 2005-2006 Expedition/Navigator vehicles built before 6/13/2005, may exhibit a clunk/grind/thump noise from the rear when the transmission is shifted, during a change in vehicle direction or on acceleration. A vibration from the driveshaft/axle area may also be exhibited. ACTION This noise may be due to the torque arm to rear axle housing attachment bolts becoming loose. It may be necessary to replace the four (4) attachment bolts, and the torque arm if distorted. The torque arm attaches at the front right side of the rear differential and the # 4 crossmember. SERVICE PROCEDURE 1. Turn off the air suspension switch if equipped. 2. Raise vehicle, refer to Workshop Manual Section 100-02. 3. Using a suitable jack-stand, support the rear axle housing. 4. Remove the four (4) torque arm to rear axle housing attachment bolts. Clean both mating surfaces. 5. Inspect the torque arm for distortion. a. If no distortion is found, replace only the four (4) torque arm to axle housing bolts and tighten to 150 lb-ft (200 N.m). (1) Remove jack. (2) Lower the vehicle. (3) Turn on the air suspension switch if equipped. b. If distortion is found, replace the torque arm and the four (4) torque arm to axle housing bolts. Refer to torque arm replacement procedure. TORQUE ARM REPLACEMENT PROCEDURE 1. Remove front torque arm bolt and torque arm. 2. Install the new torque arm and front bolt, do not tighten at this time. 3. Install the four (4) new torque arm to axle assembly bolts and tighten to 150 lb-ft (200 N.m). a. Loosen each bolt one revolution. b. Re-tighten each bolt to 150 lb-ft. (200 N.m). c. Tighten front torque arm bolt to 100 lb-ft. (135 N.m). 4. Remove jack. 5. Lower the vehicle. 6. Turn on the air suspension switch if equipped. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torque Rod > Component Information > Technical Service Bulletins > Customer Interest for Torque Rod: > 05-16-1 > Aug > 05 > A/T/Suspension - Clunk/Thump From Rear When Shifting A/T > Page 8383 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051601A 2005-2006 0.4 Hr. Expedition/Navigator: Replace The Torque Arm To Axle Housing Bolts 051601B 2005-2006 0.5 Hr. Expedition/Navigator: Replace The Torque Arm And Torque Arm Bolts DEALER CODING CONDITION BASIC PART NO. CODE 4382 33 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torque Rod > Component Information > Technical Service Bulletins > Customer Interest for Torque Rod: > 05-16-10 > Aug > 05 > Suspension/Frame - Rear End Clunk/Thump/Grind Noise Torque Rod: Customer Interest Suspension/Frame - Rear End Clunk/Thump/Grind Noise TSB 05-16-10 08/22/05 CLUNK/GRIND/THUMP NOISE - FRAME REPAIR PROCEDURE FORD: 2003 Expedition 2005-2006 Expedition LINCOLN: 2003 Navigator 2005-2006 Navigator ISSUE Some 2003 Expedition/Navigator built 3/18/2003 through 9/3/2003 and 2005-2006 built 8/2/2004 to 6/13/2005 may exhibit a clunk/grind/thump noise from the rear of the vehicle. The condition will occur when the transmission is shifted, the vehicle changes direction, or on acceleration. Vehicles may also exhibit a vibration from the driveshaft/axle area. This may be due to missing or damaged attachment bolts that secure the rear torque arm to the axle housing. In rare cases, if symptoms are ignored and the bolts are allowed to completely disengage, the differential may tip upwards allowing the driveshaft to make contact with the frame. ACTION If frame damage is found, a service kit is available to repair and reinforce the frame. Refer to the instruction sheet included in the kit. Parts Block OTHER APPLICABLE ARTICLES: 05-16-1 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 4612 33 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torque Rod > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Rod: > 05-16-1 > Aug > 05 > A/T/Suspension - Clunk/Thump From Rear When Shifting A/T Torque Rod: All Technical Service Bulletins A/T/Suspension - Clunk/Thump From Rear When Shifting A/T TSB 05-16-1 08/22/05 CLUNK/GRIND/THUMP NOISE FROM REAR OF VEHICLE WHEN TRANSMISSION IS SHIFTED - VEHICLES BUILT BEFORE 6/13/2005 FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator ISSUE Some 2005-2006 Expedition/Navigator vehicles built before 6/13/2005, may exhibit a clunk/grind/thump noise from the rear when the transmission is shifted, during a change in vehicle direction or on acceleration. A vibration from the driveshaft/axle area may also be exhibited. ACTION This noise may be due to the torque arm to rear axle housing attachment bolts becoming loose. It may be necessary to replace the four (4) attachment bolts, and the torque arm if distorted. The torque arm attaches at the front right side of the rear differential and the # 4 crossmember. SERVICE PROCEDURE 1. Turn off the air suspension switch if equipped. 2. Raise vehicle, refer to Workshop Manual Section 100-02. 3. Using a suitable jack-stand, support the rear axle housing. 4. Remove the four (4) torque arm to rear axle housing attachment bolts. Clean both mating surfaces. 5. Inspect the torque arm for distortion. a. If no distortion is found, replace only the four (4) torque arm to axle housing bolts and tighten to 150 lb-ft (200 N.m). (1) Remove jack. (2) Lower the vehicle. (3) Turn on the air suspension switch if equipped. b. If distortion is found, replace the torque arm and the four (4) torque arm to axle housing bolts. Refer to torque arm replacement procedure. TORQUE ARM REPLACEMENT PROCEDURE 1. Remove front torque arm bolt and torque arm. 2. Install the new torque arm and front bolt, do not tighten at this time. 3. Install the four (4) new torque arm to axle assembly bolts and tighten to 150 lb-ft (200 N.m). a. Loosen each bolt one revolution. b. Re-tighten each bolt to 150 lb-ft. (200 N.m). c. Tighten front torque arm bolt to 100 lb-ft. (135 N.m). 4. Remove jack. 5. Lower the vehicle. 6. Turn on the air suspension switch if equipped. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torque Rod > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Rod: > 05-16-1 > Aug > 05 > A/T/Suspension - Clunk/Thump From Rear When Shifting A/T > Page 8393 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051601A 2005-2006 0.4 Hr. Expedition/Navigator: Replace The Torque Arm To Axle Housing Bolts 051601B 2005-2006 0.5 Hr. Expedition/Navigator: Replace The Torque Arm And Torque Arm Bolts DEALER CODING CONDITION BASIC PART NO. CODE 4382 33 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torque Rod > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Rod: > 05-16-10 > Aug > 05 > Suspension/Frame - Rear End Clunk/Thump/Grind Noise Torque Rod: All Technical Service Bulletins Suspension/Frame - Rear End Clunk/Thump/Grind Noise TSB 05-16-10 08/22/05 CLUNK/GRIND/THUMP NOISE - FRAME REPAIR PROCEDURE FORD: 2003 Expedition 2005-2006 Expedition LINCOLN: 2003 Navigator 2005-2006 Navigator ISSUE Some 2003 Expedition/Navigator built 3/18/2003 through 9/3/2003 and 2005-2006 built 8/2/2004 to 6/13/2005 may exhibit a clunk/grind/thump noise from the rear of the vehicle. The condition will occur when the transmission is shifted, the vehicle changes direction, or on acceleration. Vehicles may also exhibit a vibration from the driveshaft/axle area. This may be due to missing or damaged attachment bolts that secure the rear torque arm to the axle housing. In rare cases, if symptoms are ignored and the bolts are allowed to completely disengage, the differential may tip upwards allowing the driveshaft to make contact with the frame. ACTION If frame damage is found, a service kit is available to repair and reinforce the frame. Refer to the instruction sheet included in the kit. Parts Block OTHER APPLICABLE ARTICLES: 05-16-1 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 4612 33 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications FRONT WHEEL BEARINGS High Temperature 4x4 Front Axle & Wheel Bearing Grease Ford P/N .............................................................................................................................................. ...................................................... E8TZ-19590-A Ford Specification ................................................ ................................................................................................................................... ESA-M1C198-A Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 8401 Wheel Bearing: Service and Repair Wheel Bearing and Wheel Hub Removal and Installation 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 LH rear quarter trim panel. 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. Failure to follow these instructions may result in personal injury. CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. If equipped, turn the air suspension switch to the OFF position. 2. With the vehicle in NEUTRAL, position it on a hoist. 3. NOTE: Have an assistant press the brake pedal to keep the axle from rotating. Remove and discard the rear halfshaft nut and washer. ^ To install, tighten to 300 Nm (221 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 8402 4. Using a suitable hub puller, separate the outboard CV Joint from the wheel hub. 5. CAUTION: Do not allow the caliper to hang from the brake hose or damage to the hose can result. Remove the bolts and position the caliper aside. ^ Support the caliper using mechanic's wire. ^ To install, tighten to 190 Nm (140 ft. lbs.). 6. Remove the brake disc. 7. Disconnect the wheel speed sensor electrical connector and detach the wheel speed sensor harness from the retainer. 8. Remove the bolt and detach the harness from the retainers. To install, tighten the bolt to 15 Nm (11 ft. lbs.). 9. Remove the 4 wheel bearing and hub assembly bolts, the wheel bearing assembly and the wheel speed sensor as an assembly. ^ Route the sensor wiring through the access hole in the brake shield. ^ Discard the bolts. ^ To install, tighten to 185 Nm (136 ft. lbs.). 10. If necessary, remove the wheel speed sensor bolt and the wheel speed sensor from the wheel bearing and hub assembly. ^ To install, tighten to 15 Nm (13 ft. lbs.). 11. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front axle nut ....................................................................................................................................... ...................................................... 27 Nm (20 ft.lbs.) Rear axle wheel hub retainer ........................... ...................................................................................................................................... 345 Nm (254 ft.lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations > Page 8410 C1157 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation 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 LH rear quarter trim 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. - 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 carrying out any procedure requiring the vehicle to be jacked off the ground. - Make sure the jack and jack stands are correctly 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. - If equipped with retractable running board, disable the system through the instrument cluster controls. Jacking Points - Front Jacking Points - Front The front jacking point is indicated by an arrow cutout in the frame, located behind the front tire and wheel assembly. Jacking Points - Rear Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 8415 Jacking Points - Rear CAUTION: Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and adjoining differential housing surface can occur if a floor jack or any lifting device is allowed to contact the cover at any point where the cover joins the housing. - Do not use the rear control arms as a lifting point. The rear jacking point is indicated by an arrow cutout in the frame, located in front of the rear tire and wheel assembly. LIFTING 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 LH rear quarter trim 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: Damage to suspension, exhaust and steering linkage components can occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Lifting Points - Twin Post Hoist Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 8416 Lifting Points - Twin Post Hoist Locate the front hoist adapters and rear hoist adapters (top of frame arc) as indicated. Lifting Points - Drive On Hoist Lifting Points - Drive On Hoist The vehicle is supported by tires and suspension components. Lifting Points - Floor Jack, Front Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 8417 Lifting Points - Floor Jack, Front The front can be lifted using a floor jack under the front control arm directly below the shock. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Service and Repair Tire Pressure Module: Service and Repair Tire Pressure Monitoring System Module Removal and Installation CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: The tire pressure monitoring system (TPM's) is integral to the vehicle security module (VSM) and is not serviced separately. NOTE: A new VSM module is delivered in manufacturing mode with pre-set diagnostic trouble codes (DTC's). These DTC's require that a particular set of operations to be carried out in order to clear them and enable the module for normal operations. The pre-set DTC's are as follows: ^ B2477 - Module Configuration Failure/Mismatch ^ B2868 - Left Front Tire Pressure Sensor Fault ^ B2869 - Right Front Tire Pressure Sensor Fault ^ B2870 - Left Rear Tire Pressure Sensor Fault ^ B2871 - Right Rear Tire Pressure Sensor Fault ^ C2780 - ECU in Manufacturing Mode NOTE: A re-configured VSM may also set the above codes and will need to go through the same set of procedures as a new module to enable normal operation. 1. NOTE: The steps included in the VSM removal and installation process are critical to restoring vehicle security and tire pressure monitoring system operations and will permit a new or reconfigured module to operate as intended. Each step is designed to carry out a particular operation and clear the manufacturing mode DTC's. Once these DTC's are cleared, the new or reconfigured module will enter into normal operating mode. Remove the VSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection Tire Pressure Sensor: Testing and Inspection Sensor Training (Reset Procedure) NOTE: The tire pressure monitoring system is not affected by wheel and tire rotation. NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area without radio frequency (RF) noise. RF noise is generated by electrical motor and appliance operation, cellular telephones and remote transmitters, power inverters and portable entertainment equipment. 1. Turn the ignition switch to the OFF position. 2. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. Do not wait more than 1 minute between each key cycle. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. Do not wait more than 1 minute between each key cycle. 6. The horn will sound once and the TPMS indicator will flash if train mode has been entered successfully. If equipped, the message center displays "TRAIN LF TIRE", place the special tool on the valve stem of the LF tire pressure sensor. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the TPMS module. 7. Within 2 minutes after the horn sounds, place the special tool on the valve stem of the RF tire pressure sensor. NOTE: If the VSM (TPMS module integral to VSM) does not recognize any 1 of the 4 tire pressure sensors during the tire training procedure, the horn will sound twice and the message center (if equipped) will display "TIRE NOT TRAINED REPEAT" and the procedure must be repeated. 8. Repeat Step 7 for the RR and LR tires. When the tire training procedure is complete, the horn will sound once and the message center (if equipped) will display "TIRE TRAINING MODE COMPLETE". Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 8426 Tire Pressure Sensor: Service and Repair Tire Pressure Sensor Special Tools CAUTION: Use only special tool 204-354 anytime tire pressures are measured to be sure that accurate values are obtained. CAUTION: Place the air chuck straight on the valve stem to inflate the tire. Do not cock the air chuck during the inflation cycle. Doing so can damage the valve stem and cause air leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 8427 CAUTION: Ford recommends using a round head air chuck on tire pressure sensors; it is not recommended to use air chucks with long shanks. Doing so can cause tire pressure sensor valve stem damage and loss of tire pressure. Removal NOTE: The vehicle is equipped with a light blue-colored tire pressure sensor. When installing new components, use only this tire pressure sensor. The tire pressure monitoring system (TPM's) will not operate correctly if black-colored tire pressure sensors are installed. 1. Remove the wheel and tire assembly. 2. CAUTION: Do not remove the valve stem core to relieve the tire pressure. CAUTION: If the valve stem core has been removed from the valve stem, reinstall the original valve stem core. If the original valve stem core is damaged, a nickel-plated core must be installed. Failure to use a nickel-plated core will result in corrosion and the possible loss of tire pressure. NOTE: Release the tire pressure by removing the sensor valve stem nut. With the valve stem at the 6 o'clock position, remove the sensor valve stem nut and push the sensor by hand into the tire (with the cap on). 3. Using a suitable tire machine, separate both beads of the tire from the wheel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 8428 4. CAUTION: Care should be taken not to damage the tire pressure sensor while separating the outside bead of tire from the wheel. Place the wheel and tire on the turntable of the tire machine, index-mark the valve stem and wheel weight positions, lubricate the bead of the tire and dismount the outside bead of the tire from the wheel. 5. Remove the tire pressure sensor from the tire. 6. Remove and discard the grommet from the tire pressure sensor. Installation NOTE: The vehicle is equipped with a light blue-colored tire pressure sensor. When installing new components, use only this tire pressure sensor. The TPM's will not operate correctly if black-colored tire pressure sensors are installed. 1. NOTE: Install a new sensor grommet or an air leak can occur. Install a new grommet on the tire pressure sensor. 2. NOTE: Do not allow the tire to rotate relative to the rim while mounting the tire. Lubricate and mount the outside and inside bead of the tire to the rim. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 8429 3. CAUTION: Overtightening the tire pressure sensor valve stem nut can damage the tire pressure sensor, undertightening can cause air leaks. NOTE: Sensor position is critical for correct sensor operation. The "flat" side of the sensor must be facing the wheel and the "slanted" side of the sensor must be facing away from the wheel. When properly installed, there will be a very small gap between the sensor and the wheel. NOTE: Tightening the nut to 5 Nm (44 inch lbs.) equals approximately 2 clockwise turns after the nut has been tightened by hand. Push the side wall of the tire and install the tire pressure sensor. Tighten the nut to 5 Nm (44 inch lbs.). 4. CAUTION: Use only special tool 204-354 anytime tire pressures are measured to be sure that accurate values are obtained. CAUTION: Place the air chuck straight on the valve stem to inflate the tire. Do not cock the air chuck during the inflation cycle. Doing so can damage the valve stem and cause air leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 8430 CAUTION: Ford recommends using a round head air chuck on tire pressure sensors; it is not recommended to use air chucks with long shanks. Doing so can cause tire pressure sensor valve stem damage and loss of tire pressure. CAUTION: Use only OEM valve caps (aluminum or plastic valve caps) with the tire pressure sensors. Do not use brass-threaded valve caps with the tire pressure sensors. Inflate the tire to the pressure specified on the safety certification sticker located on the driver or door pillar. 5. Install the wheel and tire assembly. 6. Train the tire pressure sensors. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Description and Operation Low Tire Pressure Indicator: Description and Operation UNDERSTANDING YOUR TIRE PRESSURE MONITORING SYSTEM (TPMS) The Tire Pressure Monitoring System measures pressure in your four road tires and sends the tire pressure readings to your vehicle every minute while you are driving and once every 6 hours when your vehicle is parked. The Low Tire Warning Lamp will turn ON if the tire pressure is 25% below the pressure listed on the Safety Compliance Certification Label (approximately 6 to 9 psi below the manufacturers recommend tire pressure). If the tire pressure increases 2 psi above the Light ON threshold, then the TPMS light will turn OFF. Once the light is illuminated, your tires are under inflated and need to be inflated to the manufacturers recommended tire pressure. Even if the light turns ON and a short time later turns OFF, your tire pressure still needs to be checked. In short, once the light has turned ON, at least one tire may be under inflated. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Description and Operation > Page 8435 Low Tire Pressure Indicator: Testing and Inspection TPM's Indicator and Vehicle Message Center Messages The TPM's indicator and vehicle message center (if equipped) sometimes displays faults that cannot be resolved by the customer. Treat these messages as TPM's faults that must be serviced. GO to Symptom Chart for the TPM's indicator operation and message center messages. See: Testing and Inspection/Symptom Related Diagnostic Procedures CAUTION: Place the air chuck straight on the valve stem to inflate the tire. Do not cock the air chuck during the inflation cycle. Doing so can damage the valve stem and cause air leaks. CAUTION: Ford recommends using a round head air chuck on tire pressure sensors; it is not recommended to use air chucks with long shanks. Doing so can cause tire pressure sensor valve stem damage and loss of tire pressure. TPM's Indicator Illuminates Continuously The TPM's indicator remains on continuously for the following condition: 1. NOTE: If the spare tire is in use, the damaged road tire must be repaired and installed on the vehicle to restore complete TPM's functionality before carrying out any diagnosis. Low Tire Pressure - The TPM's indicator is illuminated solid and the message center displays LOW TIRE PRESSURE (if equipped). This is displayed when any of the tire pressures are low. Tire pressure must be adjusted to the recommended cold placard pressure. Adjust the air pressure in tires. Refer to Information BUS for diagnosis of the CAN bus. The TPM's indicator flashes for 20 seconds after prove-out and for the following 3 reasons: 1 No communication with the TPM's Module (integral to VSM) - The TPM's indicator is illuminated when the instrument cluster (IC) has received no signals from the VSM for more than 5 seconds. If equipped, the message center displays TIRE PRESSURE MONITOR FAULT. GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures 2 Tire Pressure Sensor Fault - If equipped, the message center will display TIRE PRESSURE SENSOR FAULT when a tire pressure sensor is malfunctioning. GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures 3 Tire Pressure Monitor Fault - If equipped, the message center will display TIRE PRESSURE MONITOR FAULT when the tire pressure monitoring system is malfunctioning. GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Service and Repair Tire Pressure Module: Service and Repair Tire Pressure Monitoring System Module Removal and Installation CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: The tire pressure monitoring system (TPM's) is integral to the vehicle security module (VSM) and is not serviced separately. NOTE: A new VSM module is delivered in manufacturing mode with pre-set diagnostic trouble codes (DTC's). These DTC's require that a particular set of operations to be carried out in order to clear them and enable the module for normal operations. The pre-set DTC's are as follows: ^ B2477 - Module Configuration Failure/Mismatch ^ B2868 - Left Front Tire Pressure Sensor Fault ^ B2869 - Right Front Tire Pressure Sensor Fault ^ B2870 - Left Rear Tire Pressure Sensor Fault ^ B2871 - Right Rear Tire Pressure Sensor Fault ^ C2780 - ECU in Manufacturing Mode NOTE: A re-configured VSM may also set the above codes and will need to go through the same set of procedures as a new module to enable normal operation. 1. NOTE: The steps included in the VSM removal and installation process are critical to restoring vehicle security and tire pressure monitoring system operations and will permit a new or reconfigured module to operate as intended. Each step is designed to carry out a particular operation and clear the manufacturing mode DTC's. Once these DTC's are cleared, the new or reconfigured module will enter into normal operating mode. Remove the VSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection Tire Pressure Sensor: Testing and Inspection Sensor Training (Reset Procedure) NOTE: The tire pressure monitoring system is not affected by wheel and tire rotation. NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area without radio frequency (RF) noise. RF noise is generated by electrical motor and appliance operation, cellular telephones and remote transmitters, power inverters and portable entertainment equipment. 1. Turn the ignition switch to the OFF position. 2. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. Do not wait more than 1 minute between each key cycle. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. Do not wait more than 1 minute between each key cycle. 6. The horn will sound once and the TPMS indicator will flash if train mode has been entered successfully. If equipped, the message center displays "TRAIN LF TIRE", place the special tool on the valve stem of the LF tire pressure sensor. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the TPMS module. 7. Within 2 minutes after the horn sounds, place the special tool on the valve stem of the RF tire pressure sensor. NOTE: If the VSM (TPMS module integral to VSM) does not recognize any 1 of the 4 tire pressure sensors during the tire training procedure, the horn will sound twice and the message center (if equipped) will display "TIRE NOT TRAINED REPEAT" and the procedure must be repeated. 8. Repeat Step 7 for the RR and LR tires. When the tire training procedure is complete, the horn will sound once and the message center (if equipped) will display "TIRE TRAINING MODE COMPLETE". Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 8442 Tire Pressure Sensor: Service and Repair Tire Pressure Sensor Special Tools CAUTION: Use only special tool 204-354 anytime tire pressures are measured to be sure that accurate values are obtained. CAUTION: Place the air chuck straight on the valve stem to inflate the tire. Do not cock the air chuck during the inflation cycle. Doing so can damage the valve stem and cause air leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 8443 CAUTION: Ford recommends using a round head air chuck on tire pressure sensors; it is not recommended to use air chucks with long shanks. Doing so can cause tire pressure sensor valve stem damage and loss of tire pressure. Removal NOTE: The vehicle is equipped with a light blue-colored tire pressure sensor. When installing new components, use only this tire pressure sensor. The tire pressure monitoring system (TPM's) will not operate correctly if black-colored tire pressure sensors are installed. 1. Remove the wheel and tire assembly. 2. CAUTION: Do not remove the valve stem core to relieve the tire pressure. CAUTION: If the valve stem core has been removed from the valve stem, reinstall the original valve stem core. If the original valve stem core is damaged, a nickel-plated core must be installed. Failure to use a nickel-plated core will result in corrosion and the possible loss of tire pressure. NOTE: Release the tire pressure by removing the sensor valve stem nut. With the valve stem at the 6 o'clock position, remove the sensor valve stem nut and push the sensor by hand into the tire (with the cap on). 3. Using a suitable tire machine, separate both beads of the tire from the wheel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 8444 4. CAUTION: Care should be taken not to damage the tire pressure sensor while separating the outside bead of tire from the wheel. Place the wheel and tire on the turntable of the tire machine, index-mark the valve stem and wheel weight positions, lubricate the bead of the tire and dismount the outside bead of the tire from the wheel. 5. Remove the tire pressure sensor from the tire. 6. Remove and discard the grommet from the tire pressure sensor. Installation NOTE: The vehicle is equipped with a light blue-colored tire pressure sensor. When installing new components, use only this tire pressure sensor. The TPM's will not operate correctly if black-colored tire pressure sensors are installed. 1. NOTE: Install a new sensor grommet or an air leak can occur. Install a new grommet on the tire pressure sensor. 2. NOTE: Do not allow the tire to rotate relative to the rim while mounting the tire. Lubricate and mount the outside and inside bead of the tire to the rim. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 8445 3. CAUTION: Overtightening the tire pressure sensor valve stem nut can damage the tire pressure sensor, undertightening can cause air leaks. NOTE: Sensor position is critical for correct sensor operation. The "flat" side of the sensor must be facing the wheel and the "slanted" side of the sensor must be facing away from the wheel. When properly installed, there will be a very small gap between the sensor and the wheel. NOTE: Tightening the nut to 5 Nm (44 inch lbs.) equals approximately 2 clockwise turns after the nut has been tightened by hand. Push the side wall of the tire and install the tire pressure sensor. Tighten the nut to 5 Nm (44 inch lbs.). 4. CAUTION: Use only special tool 204-354 anytime tire pressures are measured to be sure that accurate values are obtained. CAUTION: Place the air chuck straight on the valve stem to inflate the tire. Do not cock the air chuck during the inflation cycle. Doing so can damage the valve stem and cause air leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 8446 CAUTION: Ford recommends using a round head air chuck on tire pressure sensors; it is not recommended to use air chucks with long shanks. Doing so can cause tire pressure sensor valve stem damage and loss of tire pressure. CAUTION: Use only OEM valve caps (aluminum or plastic valve caps) with the tire pressure sensors. Do not use brass-threaded valve caps with the tire pressure sensors. Inflate the tire to the pressure specified on the safety certification sticker located on the driver or door pillar. 5. Install the wheel and tire assembly. 6. Train the tire pressure sensors. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection Technical Service Bulletin # 05S35 Date: 050705 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 8455 Attachment I - Administrative Information OASIS ACTIVATED? Yes. OASIS will be activated by July 5, 2005 FSA VIN LIST ACTIVATED? Yes Available through by July 5, 2005. Owner names and addresses will be available by July 18, 2005. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states provinces and countries. Accordingly you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Inspect and if necessary correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TIRE REPLACEMENT GUIDELINES ^ Tires that fail the inspection must be replaced regardless of the mileage or the remaining tread on the tire. ^ Ford Motor Company will only pay claims for the replacement tires ordered through the Ford Tire Hotline that are listed in Attachment II under Ford Approved Replacement Tire List. Upgrades to other brand and size tires are NOT allowed. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 8456 ^ Some vehicles may be equipped with a Tire Pressure Monitoring System (TPMS). Damaged TPMS sensors are not covered under this program. Follow the instructions in Attachment III to avoid damaging the TPMS sensor while dismounting the tire from the rim. ^ If a related damage condition exists that you believe to be caused by the covered condition call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted (excluding the post-repair wheel nut re-torque procedure - see below). ^ The owner letter will direct customers to the dealer to have the wheel nuts re-tightened at 500 miles (800km) after tire replacement. Dealers are to use the related damage flag to submit claims for labor operation 05S35Z (post-repair wheel nut re-torque). Approval is not required for this labor operation. This labor operation may only be claimed once after the original repair has been completed. OWNER REFUNDS ^ Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or at their option directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Refund claims that include other non-covered repairs or those judged by Ford to be excessive will not be accepted for reimbursement. ^ This safety recall (tire tread inspection) must still be performed, even if the customer has paid for a previous tire replacement Claiming a refund will not close the recall on this vehicle. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 05S35 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. RENTAL VEHICLES Ford Motor Company will pay for a rental vehicle while a replacement tire is on order except for fuel and insurance which will be at the owner's expense. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "RENTAL" plus the number of days the vehicle was used in the Miscellaneous Expense area of the recall claim form. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Enter each unique DOT code of the "new" replacement tires on the diagnostic code entry screen in the Powertrain DTC fields. The "old" replaced tire DOT codes should be entered in the Body DTC fields. ^ Refer to ACESII manual for claims preparation and submission information. ^ Enter the full part number of the replacement tire with the quantity of tires replaced. Tires will be reimbursed at AtW Dealer cost +25% (mounting balancing valve stems and wheel weights included). - Virginia Dealers: Claim the additional 15% mark-up amount as miscellaneous expense code "TIREMU". ^ Freight is not reimbursable. (Freight charges will be credited on the dealer's Ford Parts statement.) ^ Tire disposal will be reimbursed see the Tire Disposal Allowance Attachment II. ^ Dealers may claim any applicable local waste tax - enter OTHER in the miscellaneous expense area of the claim with the actual cost. ^ Refunds or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 8457 LABOR ALLOWANCES PARTS ORDERING INFORMATION The following part is necessary when changing a tire on a vehicle that is equipped with the optional Tire Pressure Monitoring System (TPMS). FORD APPROVED REPLACEMENT TIRE LIST TIRE ORDERING INFORMATION ^ Tires must be ordered through the Ford Tire Hot Line. Identify the number of tires needed and use the "05535 Replacement Tire Order Form" to order your tires. (See Attachment IV for the tire order form.) ^ Tires will begin shipping the week of July 11, 2005 ^ Orders will be fulfilled in the order they are received. ^ Ford Tire Hot Line hours are 8AM to 8PM Monday through Friday EST. TIRE DESTRUCTION / MUTILATION Tires removed from vehicles must immediately be made unusable by either cutting the bead with bolt cutters or drilling a one-inch diameter hole through the sidewall. TIRE PRICE For latest tire prices refer to the Tire Sales Tool on the website. TIRE DISPOSAL ALLOWANCE An allowance of $4.00 per tire is being provided for tire disposal. To claim the allowance enter the dollar amount as "HANDLG" in the "MISC EXPENSE" area of the claim form. SPECIAL INSTRUCTIONS FOR POST-REPAIR TORQUE PROCEDURE Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 8458 The vehicle Owner's Guide states that each wheel that is removed and reinstalled must have the wheel nuts re-tightened at 500 miles (800km) after service. This is required to permit the wheel clamping system to seat correctly so that the wheel nuts will hold a uniform clamp load and remain fully tightened. To claim this operation you must file a related damage claim using labor operation 05S35Z. This labor operation includes time to check the torque on all the wheel nuts. Attachment III - Technical Information OVERVIEW This program involves inspecting all four (4) tires of the vehicle for tread damaged caused by a piece of metal on the conveyor line during vehicle assembly. INSPECTION 1. If equipped, turn the air suspension switch to the OFF position. 2. Raise the vehicle on a hoist and inspect all four (4) tires for tread damage. See Figure 1. ^ If no tread damage is found, lower the vehicle, turn on the air suspension if equipped, and release the vehicle. ^ Any tire found to have damaged tread must be replaced. Proceed to Tire Replacement. TIRE REPLACEMENT CAUTION: Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 8459 If the vehicle is equipped with a Tire Pressure Monitoring System (TPMS), specific procedures must be followed to remove and install the tire or damage to the TPMS sensors will occur. Related damage claims for TPMS sensors will be rejected. NOTE: Vehicles equipped with TPMS can be identified by the presence of a metallic valve stem at each wheel. Vehicles without TPMS will have rubber valve stems. NOTE: While the Workshop Repair Manual does not provide actual tire replacement procedures, it does provide procedures for TPMS sensor removal and installation. To prevent damage to the sensor, it must be removed and installed during tire removal and installation. Refer to Section 204-04 of the ONLINE version of the 2006 Model Year Expedition/Navigator Workshop Repair Manual for the most up-to-date service information available. Again, related damage claims for TPMS sensors will be rejected. 1. CAUTION: Do not remove the valve core from TPMS valve stem. Remove the tire from the wheel. If the vehicle is equipped with TPMS, refer to the Workshop Repair Manual for special instructions regarding the TPMS sensor removal. 2. For vehicles without TPMS, install a new rubber valve stem. 3. Mount the new tire onto the wheel. If the vehicle is equipped with TPMS, refer to the Workshop Repair Manual for special instructions regarding the TPMS sensor installation. 4. Balance the wheel/tire assembly, then install it on the vehicle. 5. Tighten the wheel nuts to 204 Nm (150 lb-ft). 6. Lower the hoist and if equipped, turn the air suspension switch to the ON position. 7. Proceed to Tire Destruction/Mutilation. TIRE DESTRUCTION/MUTILATION Tires removed from vehicles must immediately be made unusable by either cutting the bead with bolt cutters or drilling a one-inch diameter hole through the sidewall. SPECIAL INSTRUCTIONS FOR POST REPAIR RETIGHTEN PROCEDURE WARNING: Re-tighten the wheel nuts at 800 km (500 miles) after any wheel change or any time the wheel nuts are loosened. Failure to follow these instructions may result in personal injury. The Owner Guide and workshop repair manual recommend that each wheel removed and reinstalled must have the wheel nuts re-tightened at 800 km (500 miles) after service. Wheel nut torque specification is 204 Nm (150 lb-ft). This is required to permit the wheel clamping system to seat correctly so that the wheel lug nuts will hold a uniform clamp load and remain fully tightened. To claim this operation, refer to Attachment II. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 8460 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 8461 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 8462 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 8463 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > NHTSA05V310000 > Jul > 05 > Recall - Tire Tread Inspection for Damage Tires: Recalls Recall - Tire Tread Inspection for Damage MAKE/MODELS: MODEL/BUILD YEARS: Ford/Expedition 2006 Lincoln/Navigator 2006 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V310000 MFG'S REPORT DATE: July 05, 2005 COMPONENT: Tires: Tread/Belt POTENTIAL NUMBER OF UNITS AFFECTED: 10061 SUMMARY: On certain sport utility vehicles, the front and rear tires on the driver's side of affected vehicles may have been damaged at the center tread during production. CONSEQUENCE: Over time, the damage may be sufficient to allow belt corrosion ultimately leading to a tread separation, which could result in a crash. REMEDY: Dealers will inspect all four tires (to ensure inspection of the left hand side tires that may have been rotated to the other side of the vehicle) for tire tread damage and, if necessary, replace the damaged tire. The recall began on July 13, 2005. Owners should contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S35. Please note that this program will expire on December 31, 2005. 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns Tires: Customer Interest 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns TSB 08-21-11 10/27/08 4 WHEEL DRIVE/ALL WHEEL DRIVE - WITH CONTROL TRAC - SHUDDER ON ACCELERATION/DECELERATION OR BINDING ON SLOW TURNS FORD: 1997-2008 Expedition, Explorer 2006-2008 F-150 2007-2008 Explorer Sport Trac 2008 F-150 LINCOLN: 1998-2008 Navigator 2003-2005 Aviator MERCURY: 2005 Mountaineer 2006-2008 Mountaineer ISSUE Various 1997-2008 vehicles equipped with either 4 wheel drive or all wheel drive and equipped with control trac may exhibit a shudder on acceleration/deceleration, binding in slow speed turns or noise from the front driveline and/or transfer case. The shudder/binding will occur with the vehicle being operated in the awd/auto 4x4 mode. The shudder/binding may be due to incorrect tire circumference or improper tire inflation pressures. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE THIS DOES NOT APPLY TO 2006-2008 MOUNTAINEER WITH A 4.0L ENGINE OR 2007-2008 EXPLORER AND SPORT TRAC WITH 20 INCH WHEELS. NOTE VEHICLES ON THE LIST MAY REQUIRE REPLACEMENT OF TIRE/S IF THE TIRE CIRCUMFERENCE AVERAGE BETWEEN THE FRONT AND REAR AXLES ARE OUTSIDE OF THE 1/2 INCH SPECIFICATION OR IF THE TIRE CIRCUMFERENCE FROM SIDE TO SIDE ON EITHER AXLE EXCEEDS 1/2 INCH DIFFERENCE, THE SMALLER TIRE(S) MUST BE REPLACED. NOTE REVIEW THE WARRANTY AND POLICY MANUAL FOR FORD MOTOR COMPANY TIRE REPLACEMENT WARRANTY BEFORE PERFORMING THE SERVICE PROCEDURE. NOTE ONLY USE REPLACEMENT TIRE AND WHEEL THAT ARE THE SAME SIZE, LOAD INDEX, SPEED RATING AND TYPE (SUCH AS P-METRIC VERSUS LT-METRIC OR ALL-SEASON VERSUS ALL-TERRAIN) AS THOSE ORIGINALLY PROVIDED BY FORD. THE RECOMMENDED TIRE AND WHEEL SIZE MAY BE FOUND ON EITHER THE SAFETY COMPLIANCE CERTIFICATION LABEL OR THE TIRE LABEL WHICH IS LOCATED ON THE B-PILLAR OR EDGE OF THE DRIVER'S DOOR. NOTE ON SOME 4WD MODELS, THE INITIAL SHIFT FROM 2WD TO 4WD WHILE THE VEHICLE IS MOVING CAN CAUSE A MOMENTARY CLUNK AND/OR BRIEF RATCHETING SOUND. THESE SOUNDS ARE NORMAL AS THE FRONT DRIVETRAIN COMES UP TO SPEED AND IS NOT CAUSE FOR CONCERN. 1. Review the tire label for correct tire size and tire inflation pressures located at the B-Pillar of the driver's door. 2. If the tire size does not match the label, this procedure does not apply, follow normal Workshop Manual (WSM) diagnostics. 3. If the tire size is correct, ensure tire pressures are within specifications. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 8473 4. Raise the vehicle on the hoist, refer to Workshop Manual, Section 100-02. 5. Disconnect all wiring going to the transfer case and road test. 6. Is the shudder/binding present? a. If the shudder/binding is still present, do not continue with this procedure, continue with WSM normal diagnostic for 4X4. b. If the shudder/binding is gone, proceed to Step 7. 7. Raise the vehicle on the hoist and reconnect all the wiring previously disconnected. 8. Using a tailor's tape or flexible measuring tape and measure the circumference of all four (4) tires and record the measurements. (Figure 1) 9. Calculate the average of the circumference of the two (2) front tires and calculate the average of the circumference of the two (2) rear tires. (Figure 2) 10. If the difference between these two averages is greater than 1/2" (12.7 mm), front to back or side to side, replace the smallest circumference tire(s) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 8474 and remeasure the tire averages. Refer to WSM, Section 204-04 for tire replacement. NOTE WARRANTY COVERAGE ELIGIBILITY STARTS WITH 2007 NEW VEHICLE LIMITED WARRANTY COVERAGE. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082111A 2003-2008 Expedition, 1.1 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace One (1) Tire (Do Not Use With 1007A) 082111A 1997-2002 Expedition, 1.0 Hr. 1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace One (1) Tire (Do Not Use With 1007A) 082111B 2003-2008 Expedition, 1.4 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace TWO Tires. (Do Not Use With 1007A) 082111B 1997-2002 Expedition, 1.2 Hrs. 1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Two (2) Tires (Do Not Use With 1007A) 082111C 2003-2008 Expedition, 1.7 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do Not Use With 1007A) 082111C 1997-2002 Expedition, 1.4 Hrs. 1998-2002 Navigator, 2006-2008 F-150 Harley Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 8475 Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do Not Use With 1007A) DEALER CODING CONDITION BASIC PART NO. CODE 7A195 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns Tires: All Technical Service Bulletins 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns TSB 08-21-11 10/27/08 4 WHEEL DRIVE/ALL WHEEL DRIVE - WITH CONTROL TRAC - SHUDDER ON ACCELERATION/DECELERATION OR BINDING ON SLOW TURNS FORD: 1997-2008 Expedition, Explorer 2006-2008 F-150 2007-2008 Explorer Sport Trac 2008 F-150 LINCOLN: 1998-2008 Navigator 2003-2005 Aviator MERCURY: 2005 Mountaineer 2006-2008 Mountaineer ISSUE Various 1997-2008 vehicles equipped with either 4 wheel drive or all wheel drive and equipped with control trac may exhibit a shudder on acceleration/deceleration, binding in slow speed turns or noise from the front driveline and/or transfer case. The shudder/binding will occur with the vehicle being operated in the awd/auto 4x4 mode. The shudder/binding may be due to incorrect tire circumference or improper tire inflation pressures. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE THIS DOES NOT APPLY TO 2006-2008 MOUNTAINEER WITH A 4.0L ENGINE OR 2007-2008 EXPLORER AND SPORT TRAC WITH 20 INCH WHEELS. NOTE VEHICLES ON THE LIST MAY REQUIRE REPLACEMENT OF TIRE/S IF THE TIRE CIRCUMFERENCE AVERAGE BETWEEN THE FRONT AND REAR AXLES ARE OUTSIDE OF THE 1/2 INCH SPECIFICATION OR IF THE TIRE CIRCUMFERENCE FROM SIDE TO SIDE ON EITHER AXLE EXCEEDS 1/2 INCH DIFFERENCE, THE SMALLER TIRE(S) MUST BE REPLACED. NOTE REVIEW THE WARRANTY AND POLICY MANUAL FOR FORD MOTOR COMPANY TIRE REPLACEMENT WARRANTY BEFORE PERFORMING THE SERVICE PROCEDURE. NOTE ONLY USE REPLACEMENT TIRE AND WHEEL THAT ARE THE SAME SIZE, LOAD INDEX, SPEED RATING AND TYPE (SUCH AS P-METRIC VERSUS LT-METRIC OR ALL-SEASON VERSUS ALL-TERRAIN) AS THOSE ORIGINALLY PROVIDED BY FORD. THE RECOMMENDED TIRE AND WHEEL SIZE MAY BE FOUND ON EITHER THE SAFETY COMPLIANCE CERTIFICATION LABEL OR THE TIRE LABEL WHICH IS LOCATED ON THE B-PILLAR OR EDGE OF THE DRIVER'S DOOR. NOTE ON SOME 4WD MODELS, THE INITIAL SHIFT FROM 2WD TO 4WD WHILE THE VEHICLE IS MOVING CAN CAUSE A MOMENTARY CLUNK AND/OR BRIEF RATCHETING SOUND. THESE SOUNDS ARE NORMAL AS THE FRONT DRIVETRAIN COMES UP TO SPEED AND IS NOT CAUSE FOR CONCERN. 1. Review the tire label for correct tire size and tire inflation pressures located at the B-Pillar of the driver's door. 2. If the tire size does not match the label, this procedure does not apply, follow normal Workshop Manual (WSM) diagnostics. 3. If the tire size is correct, ensure tire pressures are within specifications. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 8481 4. Raise the vehicle on the hoist, refer to Workshop Manual, Section 100-02. 5. Disconnect all wiring going to the transfer case and road test. 6. Is the shudder/binding present? a. If the shudder/binding is still present, do not continue with this procedure, continue with WSM normal diagnostic for 4X4. b. If the shudder/binding is gone, proceed to Step 7. 7. Raise the vehicle on the hoist and reconnect all the wiring previously disconnected. 8. Using a tailor's tape or flexible measuring tape and measure the circumference of all four (4) tires and record the measurements. (Figure 1) 9. Calculate the average of the circumference of the two (2) front tires and calculate the average of the circumference of the two (2) rear tires. (Figure 2) 10. If the difference between these two averages is greater than 1/2" (12.7 mm), front to back or side to side, replace the smallest circumference tire(s) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 8482 and remeasure the tire averages. Refer to WSM, Section 204-04 for tire replacement. NOTE WARRANTY COVERAGE ELIGIBILITY STARTS WITH 2007 NEW VEHICLE LIMITED WARRANTY COVERAGE. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082111A 2003-2008 Expedition, 1.1 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace One (1) Tire (Do Not Use With 1007A) 082111A 1997-2002 Expedition, 1.0 Hr. 1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace One (1) Tire (Do Not Use With 1007A) 082111B 2003-2008 Expedition, 1.4 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace TWO Tires. (Do Not Use With 1007A) 082111B 1997-2002 Expedition, 1.2 Hrs. 1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Two (2) Tires (Do Not Use With 1007A) 082111C 2003-2008 Expedition, 1.7 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do Not Use With 1007A) 082111C 1997-2002 Expedition, 1.4 Hrs. 1998-2002 Navigator, 2006-2008 F-150 Harley Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 8483 Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do Not Use With 1007A) DEALER CODING CONDITION BASIC PART NO. CODE 7A195 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection Technical Service Bulletin # 05S35 Date: 050705 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 8488 Attachment I - Administrative Information OASIS ACTIVATED? Yes. OASIS will be activated by July 5, 2005 FSA VIN LIST ACTIVATED? Yes Available through by July 5, 2005. Owner names and addresses will be available by July 18, 2005. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states provinces and countries. Accordingly you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Inspect and if necessary correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TIRE REPLACEMENT GUIDELINES ^ Tires that fail the inspection must be replaced regardless of the mileage or the remaining tread on the tire. ^ Ford Motor Company will only pay claims for the replacement tires ordered through the Ford Tire Hotline that are listed in Attachment II under Ford Approved Replacement Tire List. Upgrades to other brand and size tires are NOT allowed. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 8489 ^ Some vehicles may be equipped with a Tire Pressure Monitoring System (TPMS). Damaged TPMS sensors are not covered under this program. Follow the instructions in Attachment III to avoid damaging the TPMS sensor while dismounting the tire from the rim. ^ If a related damage condition exists that you believe to be caused by the covered condition call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted (excluding the post-repair wheel nut re-torque procedure - see below). ^ The owner letter will direct customers to the dealer to have the wheel nuts re-tightened at 500 miles (800km) after tire replacement. Dealers are to use the related damage flag to submit claims for labor operation 05S35Z (post-repair wheel nut re-torque). Approval is not required for this labor operation. This labor operation may only be claimed once after the original repair has been completed. OWNER REFUNDS ^ Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or at their option directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Refund claims that include other non-covered repairs or those judged by Ford to be excessive will not be accepted for reimbursement. ^ This safety recall (tire tread inspection) must still be performed, even if the customer has paid for a previous tire replacement Claiming a refund will not close the recall on this vehicle. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 05S35 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. RENTAL VEHICLES Ford Motor Company will pay for a rental vehicle while a replacement tire is on order except for fuel and insurance which will be at the owner's expense. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "RENTAL" plus the number of days the vehicle was used in the Miscellaneous Expense area of the recall claim form. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Enter each unique DOT code of the "new" replacement tires on the diagnostic code entry screen in the Powertrain DTC fields. The "old" replaced tire DOT codes should be entered in the Body DTC fields. ^ Refer to ACESII manual for claims preparation and submission information. ^ Enter the full part number of the replacement tire with the quantity of tires replaced. Tires will be reimbursed at AtW Dealer cost +25% (mounting balancing valve stems and wheel weights included). - Virginia Dealers: Claim the additional 15% mark-up amount as miscellaneous expense code "TIREMU". ^ Freight is not reimbursable. (Freight charges will be credited on the dealer's Ford Parts statement.) ^ Tire disposal will be reimbursed see the Tire Disposal Allowance Attachment II. ^ Dealers may claim any applicable local waste tax - enter OTHER in the miscellaneous expense area of the claim with the actual cost. ^ Refunds or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 8490 LABOR ALLOWANCES PARTS ORDERING INFORMATION The following part is necessary when changing a tire on a vehicle that is equipped with the optional Tire Pressure Monitoring System (TPMS). FORD APPROVED REPLACEMENT TIRE LIST TIRE ORDERING INFORMATION ^ Tires must be ordered through the Ford Tire Hot Line. Identify the number of tires needed and use the "05535 Replacement Tire Order Form" to order your tires. (See Attachment IV for the tire order form.) ^ Tires will begin shipping the week of July 11, 2005 ^ Orders will be fulfilled in the order they are received. ^ Ford Tire Hot Line hours are 8AM to 8PM Monday through Friday EST. TIRE DESTRUCTION / MUTILATION Tires removed from vehicles must immediately be made unusable by either cutting the bead with bolt cutters or drilling a one-inch diameter hole through the sidewall. TIRE PRICE For latest tire prices refer to the Tire Sales Tool on the website. TIRE DISPOSAL ALLOWANCE An allowance of $4.00 per tire is being provided for tire disposal. To claim the allowance enter the dollar amount as "HANDLG" in the "MISC EXPENSE" area of the claim form. SPECIAL INSTRUCTIONS FOR POST-REPAIR TORQUE PROCEDURE Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 8491 The vehicle Owner's Guide states that each wheel that is removed and reinstalled must have the wheel nuts re-tightened at 500 miles (800km) after service. This is required to permit the wheel clamping system to seat correctly so that the wheel nuts will hold a uniform clamp load and remain fully tightened. To claim this operation you must file a related damage claim using labor operation 05S35Z. This labor operation includes time to check the torque on all the wheel nuts. Attachment III - Technical Information OVERVIEW This program involves inspecting all four (4) tires of the vehicle for tread damaged caused by a piece of metal on the conveyor line during vehicle assembly. INSPECTION 1. If equipped, turn the air suspension switch to the OFF position. 2. Raise the vehicle on a hoist and inspect all four (4) tires for tread damage. See Figure 1. ^ If no tread damage is found, lower the vehicle, turn on the air suspension if equipped, and release the vehicle. ^ Any tire found to have damaged tread must be replaced. Proceed to Tire Replacement. TIRE REPLACEMENT CAUTION: Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 8492 If the vehicle is equipped with a Tire Pressure Monitoring System (TPMS), specific procedures must be followed to remove and install the tire or damage to the TPMS sensors will occur. Related damage claims for TPMS sensors will be rejected. NOTE: Vehicles equipped with TPMS can be identified by the presence of a metallic valve stem at each wheel. Vehicles without TPMS will have rubber valve stems. NOTE: While the Workshop Repair Manual does not provide actual tire replacement procedures, it does provide procedures for TPMS sensor removal and installation. To prevent damage to the sensor, it must be removed and installed during tire removal and installation. Refer to Section 204-04 of the ONLINE version of the 2006 Model Year Expedition/Navigator Workshop Repair Manual for the most up-to-date service information available. Again, related damage claims for TPMS sensors will be rejected. 1. CAUTION: Do not remove the valve core from TPMS valve stem. Remove the tire from the wheel. If the vehicle is equipped with TPMS, refer to the Workshop Repair Manual for special instructions regarding the TPMS sensor removal. 2. For vehicles without TPMS, install a new rubber valve stem. 3. Mount the new tire onto the wheel. If the vehicle is equipped with TPMS, refer to the Workshop Repair Manual for special instructions regarding the TPMS sensor installation. 4. Balance the wheel/tire assembly, then install it on the vehicle. 5. Tighten the wheel nuts to 204 Nm (150 lb-ft). 6. Lower the hoist and if equipped, turn the air suspension switch to the ON position. 7. Proceed to Tire Destruction/Mutilation. TIRE DESTRUCTION/MUTILATION Tires removed from vehicles must immediately be made unusable by either cutting the bead with bolt cutters or drilling a one-inch diameter hole through the sidewall. SPECIAL INSTRUCTIONS FOR POST REPAIR RETIGHTEN PROCEDURE WARNING: Re-tighten the wheel nuts at 800 km (500 miles) after any wheel change or any time the wheel nuts are loosened. Failure to follow these instructions may result in personal injury. The Owner Guide and workshop repair manual recommend that each wheel removed and reinstalled must have the wheel nuts re-tightened at 800 km (500 miles) after service. Wheel nut torque specification is 204 Nm (150 lb-ft). This is required to permit the wheel clamping system to seat correctly so that the wheel lug nuts will hold a uniform clamp load and remain fully tightened. To claim this operation, refer to Attachment II. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 8493 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 8494 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 8495 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 8496 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > NHTSA05V310000 > Jul > 05 > Recall - Tire Tread Inspection for Damage Tires: All Technical Service Bulletins Recall - Tire Tread Inspection for Damage MAKE/MODELS: MODEL/BUILD YEARS: Ford/Expedition 2006 Lincoln/Navigator 2006 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V310000 MFG'S REPORT DATE: July 05, 2005 COMPONENT: Tires: Tread/Belt POTENTIAL NUMBER OF UNITS AFFECTED: 10061 SUMMARY: On certain sport utility vehicles, the front and rear tires on the driver's side of affected vehicles may have been damaged at the center tread during production. CONSEQUENCE: Over time, the damage may be sufficient to allow belt corrosion ultimately leading to a tread separation, which could result in a crash. REMEDY: Dealers will inspect all four tires (to ensure inspection of the left hand side tires that may have been rotated to the other side of the vehicle) for tire tread damage and, if necessary, replace the damaged tire. The recall began on July 13, 2005. Owners should contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S35. Please note that this program will expire on December 31, 2005. 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns Tires: All Technical Service Bulletins 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns TSB 08-21-11 10/27/08 4 WHEEL DRIVE/ALL WHEEL DRIVE - WITH CONTROL TRAC - SHUDDER ON ACCELERATION/DECELERATION OR BINDING ON SLOW TURNS FORD: 1997-2008 Expedition, Explorer 2006-2008 F-150 2007-2008 Explorer Sport Trac 2008 F-150 LINCOLN: 1998-2008 Navigator 2003-2005 Aviator MERCURY: 2005 Mountaineer 2006-2008 Mountaineer ISSUE Various 1997-2008 vehicles equipped with either 4 wheel drive or all wheel drive and equipped with control trac may exhibit a shudder on acceleration/deceleration, binding in slow speed turns or noise from the front driveline and/or transfer case. The shudder/binding will occur with the vehicle being operated in the awd/auto 4x4 mode. The shudder/binding may be due to incorrect tire circumference or improper tire inflation pressures. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE THIS DOES NOT APPLY TO 2006-2008 MOUNTAINEER WITH A 4.0L ENGINE OR 2007-2008 EXPLORER AND SPORT TRAC WITH 20 INCH WHEELS. NOTE VEHICLES ON THE LIST MAY REQUIRE REPLACEMENT OF TIRE/S IF THE TIRE CIRCUMFERENCE AVERAGE BETWEEN THE FRONT AND REAR AXLES ARE OUTSIDE OF THE 1/2 INCH SPECIFICATION OR IF THE TIRE CIRCUMFERENCE FROM SIDE TO SIDE ON EITHER AXLE EXCEEDS 1/2 INCH DIFFERENCE, THE SMALLER TIRE(S) MUST BE REPLACED. NOTE REVIEW THE WARRANTY AND POLICY MANUAL FOR FORD MOTOR COMPANY TIRE REPLACEMENT WARRANTY BEFORE PERFORMING THE SERVICE PROCEDURE. NOTE ONLY USE REPLACEMENT TIRE AND WHEEL THAT ARE THE SAME SIZE, LOAD INDEX, SPEED RATING AND TYPE (SUCH AS P-METRIC VERSUS LT-METRIC OR ALL-SEASON VERSUS ALL-TERRAIN) AS THOSE ORIGINALLY PROVIDED BY FORD. THE RECOMMENDED TIRE AND WHEEL SIZE MAY BE FOUND ON EITHER THE SAFETY COMPLIANCE CERTIFICATION LABEL OR THE TIRE LABEL WHICH IS LOCATED ON THE B-PILLAR OR EDGE OF THE DRIVER'S DOOR. NOTE ON SOME 4WD MODELS, THE INITIAL SHIFT FROM 2WD TO 4WD WHILE THE VEHICLE IS MOVING CAN CAUSE A MOMENTARY CLUNK AND/OR BRIEF RATCHETING SOUND. THESE SOUNDS ARE NORMAL AS THE FRONT DRIVETRAIN COMES UP TO SPEED AND IS NOT CAUSE FOR CONCERN. 1. Review the tire label for correct tire size and tire inflation pressures located at the B-Pillar of the driver's door. 2. If the tire size does not match the label, this procedure does not apply, follow normal Workshop Manual (WSM) diagnostics. 3. If the tire size is correct, ensure tire pressures are within specifications. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 8506 4. Raise the vehicle on the hoist, refer to Workshop Manual, Section 100-02. 5. Disconnect all wiring going to the transfer case and road test. 6. Is the shudder/binding present? a. If the shudder/binding is still present, do not continue with this procedure, continue with WSM normal diagnostic for 4X4. b. If the shudder/binding is gone, proceed to Step 7. 7. Raise the vehicle on the hoist and reconnect all the wiring previously disconnected. 8. Using a tailor's tape or flexible measuring tape and measure the circumference of all four (4) tires and record the measurements. (Figure 1) 9. Calculate the average of the circumference of the two (2) front tires and calculate the average of the circumference of the two (2) rear tires. (Figure 2) 10. If the difference between these two averages is greater than 1/2" (12.7 mm), front to back or side to side, replace the smallest circumference tire(s) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 8507 and remeasure the tire averages. Refer to WSM, Section 204-04 for tire replacement. NOTE WARRANTY COVERAGE ELIGIBILITY STARTS WITH 2007 NEW VEHICLE LIMITED WARRANTY COVERAGE. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082111A 2003-2008 Expedition, 1.1 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace One (1) Tire (Do Not Use With 1007A) 082111A 1997-2002 Expedition, 1.0 Hr. 1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace One (1) Tire (Do Not Use With 1007A) 082111B 2003-2008 Expedition, 1.4 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace TWO Tires. (Do Not Use With 1007A) 082111B 1997-2002 Expedition, 1.2 Hrs. 1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Two (2) Tires (Do Not Use With 1007A) 082111C 2003-2008 Expedition, 1.7 Hrs. Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do Not Use With 1007A) 082111C 1997-2002 Expedition, 1.4 Hrs. 1998-2002 Navigator, 2006-2008 F-150 Harley Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 8508 Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do Not Use With 1007A) DEALER CODING CONDITION BASIC PART NO. CODE 7A195 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection Technical Service Bulletin # 05S35 Date: 050705 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 8514 Attachment I - Administrative Information OASIS ACTIVATED? Yes. OASIS will be activated by July 5, 2005 FSA VIN LIST ACTIVATED? Yes Available through by July 5, 2005. Owner names and addresses will be available by July 18, 2005. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states provinces and countries. Accordingly you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Inspect and if necessary correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TIRE REPLACEMENT GUIDELINES ^ Tires that fail the inspection must be replaced regardless of the mileage or the remaining tread on the tire. ^ Ford Motor Company will only pay claims for the replacement tires ordered through the Ford Tire Hotline that are listed in Attachment II under Ford Approved Replacement Tire List. Upgrades to other brand and size tires are NOT allowed. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 8515 ^ Some vehicles may be equipped with a Tire Pressure Monitoring System (TPMS). Damaged TPMS sensors are not covered under this program. Follow the instructions in Attachment III to avoid damaging the TPMS sensor while dismounting the tire from the rim. ^ If a related damage condition exists that you believe to be caused by the covered condition call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted (excluding the post-repair wheel nut re-torque procedure - see below). ^ The owner letter will direct customers to the dealer to have the wheel nuts re-tightened at 500 miles (800km) after tire replacement. Dealers are to use the related damage flag to submit claims for labor operation 05S35Z (post-repair wheel nut re-torque). Approval is not required for this labor operation. This labor operation may only be claimed once after the original repair has been completed. OWNER REFUNDS ^ Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or at their option directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Refund claims that include other non-covered repairs or those judged by Ford to be excessive will not be accepted for reimbursement. ^ This safety recall (tire tread inspection) must still be performed, even if the customer has paid for a previous tire replacement Claiming a refund will not close the recall on this vehicle. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 05S35 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. RENTAL VEHICLES Ford Motor Company will pay for a rental vehicle while a replacement tire is on order except for fuel and insurance which will be at the owner's expense. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "RENTAL" plus the number of days the vehicle was used in the Miscellaneous Expense area of the recall claim form. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Enter each unique DOT code of the "new" replacement tires on the diagnostic code entry screen in the Powertrain DTC fields. The "old" replaced tire DOT codes should be entered in the Body DTC fields. ^ Refer to ACESII manual for claims preparation and submission information. ^ Enter the full part number of the replacement tire with the quantity of tires replaced. Tires will be reimbursed at AtW Dealer cost +25% (mounting balancing valve stems and wheel weights included). - Virginia Dealers: Claim the additional 15% mark-up amount as miscellaneous expense code "TIREMU". ^ Freight is not reimbursable. (Freight charges will be credited on the dealer's Ford Parts statement.) ^ Tire disposal will be reimbursed see the Tire Disposal Allowance Attachment II. ^ Dealers may claim any applicable local waste tax - enter OTHER in the miscellaneous expense area of the claim with the actual cost. ^ Refunds or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 8516 LABOR ALLOWANCES PARTS ORDERING INFORMATION The following part is necessary when changing a tire on a vehicle that is equipped with the optional Tire Pressure Monitoring System (TPMS). FORD APPROVED REPLACEMENT TIRE LIST TIRE ORDERING INFORMATION ^ Tires must be ordered through the Ford Tire Hot Line. Identify the number of tires needed and use the "05535 Replacement Tire Order Form" to order your tires. (See Attachment IV for the tire order form.) ^ Tires will begin shipping the week of July 11, 2005 ^ Orders will be fulfilled in the order they are received. ^ Ford Tire Hot Line hours are 8AM to 8PM Monday through Friday EST. TIRE DESTRUCTION / MUTILATION Tires removed from vehicles must immediately be made unusable by either cutting the bead with bolt cutters or drilling a one-inch diameter hole through the sidewall. TIRE PRICE For latest tire prices refer to the Tire Sales Tool on the website. TIRE DISPOSAL ALLOWANCE An allowance of $4.00 per tire is being provided for tire disposal. To claim the allowance enter the dollar amount as "HANDLG" in the "MISC EXPENSE" area of the claim form. SPECIAL INSTRUCTIONS FOR POST-REPAIR TORQUE PROCEDURE Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 8517 The vehicle Owner's Guide states that each wheel that is removed and reinstalled must have the wheel nuts re-tightened at 500 miles (800km) after service. This is required to permit the wheel clamping system to seat correctly so that the wheel nuts will hold a uniform clamp load and remain fully tightened. To claim this operation you must file a related damage claim using labor operation 05S35Z. This labor operation includes time to check the torque on all the wheel nuts. Attachment III - Technical Information OVERVIEW This program involves inspecting all four (4) tires of the vehicle for tread damaged caused by a piece of metal on the conveyor line during vehicle assembly. INSPECTION 1. If equipped, turn the air suspension switch to the OFF position. 2. Raise the vehicle on a hoist and inspect all four (4) tires for tread damage. See Figure 1. ^ If no tread damage is found, lower the vehicle, turn on the air suspension if equipped, and release the vehicle. ^ Any tire found to have damaged tread must be replaced. Proceed to Tire Replacement. TIRE REPLACEMENT CAUTION: Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 8518 If the vehicle is equipped with a Tire Pressure Monitoring System (TPMS), specific procedures must be followed to remove and install the tire or damage to the TPMS sensors will occur. Related damage claims for TPMS sensors will be rejected. NOTE: Vehicles equipped with TPMS can be identified by the presence of a metallic valve stem at each wheel. Vehicles without TPMS will have rubber valve stems. NOTE: While the Workshop Repair Manual does not provide actual tire replacement procedures, it does provide procedures for TPMS sensor removal and installation. To prevent damage to the sensor, it must be removed and installed during tire removal and installation. Refer to Section 204-04 of the ONLINE version of the 2006 Model Year Expedition/Navigator Workshop Repair Manual for the most up-to-date service information available. Again, related damage claims for TPMS sensors will be rejected. 1. CAUTION: Do not remove the valve core from TPMS valve stem. Remove the tire from the wheel. If the vehicle is equipped with TPMS, refer to the Workshop Repair Manual for special instructions regarding the TPMS sensor removal. 2. For vehicles without TPMS, install a new rubber valve stem. 3. Mount the new tire onto the wheel. If the vehicle is equipped with TPMS, refer to the Workshop Repair Manual for special instructions regarding the TPMS sensor installation. 4. Balance the wheel/tire assembly, then install it on the vehicle. 5. Tighten the wheel nuts to 204 Nm (150 lb-ft). 6. Lower the hoist and if equipped, turn the air suspension switch to the ON position. 7. Proceed to Tire Destruction/Mutilation. TIRE DESTRUCTION/MUTILATION Tires removed from vehicles must immediately be made unusable by either cutting the bead with bolt cutters or drilling a one-inch diameter hole through the sidewall. SPECIAL INSTRUCTIONS FOR POST REPAIR RETIGHTEN PROCEDURE WARNING: Re-tighten the wheel nuts at 800 km (500 miles) after any wheel change or any time the wheel nuts are loosened. Failure to follow these instructions may result in personal injury. The Owner Guide and workshop repair manual recommend that each wheel removed and reinstalled must have the wheel nuts re-tightened at 800 km (500 miles) after service. Wheel nut torque specification is 204 Nm (150 lb-ft). This is required to permit the wheel clamping system to seat correctly so that the wheel lug nuts will hold a uniform clamp load and remain fully tightened. To claim this operation, refer to Attachment II. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 8519 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 8520 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 8521 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 05S35 > Jul > 05 > Recall - Tire Tread Inspection > Page 8522 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > NHTSA05V310000 > Jul > 05 > Recall - Tire Tread Inspection for Damage Tires: All Technical Service Bulletins Recall - Tire Tread Inspection for Damage MAKE/MODELS: MODEL/BUILD YEARS: Ford/Expedition 2006 Lincoln/Navigator 2006 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V310000 MFG'S REPORT DATE: July 05, 2005 COMPONENT: Tires: Tread/Belt POTENTIAL NUMBER OF UNITS AFFECTED: 10061 SUMMARY: On certain sport utility vehicles, the front and rear tires on the driver's side of affected vehicles may have been damaged at the center tread during production. CONSEQUENCE: Over time, the damage may be sufficient to allow belt corrosion ultimately leading to a tread separation, which could result in a crash. REMEDY: Dealers will inspect all four tires (to ensure inspection of the left hand side tires that may have been rotated to the other side of the vehicle) for tire tread damage and, if necessary, replace the damaged tire. The recall began on July 13, 2005. Owners should contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S35. Please note that this program will expire on December 31, 2005. 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications FRONT WHEEL BEARINGS High Temperature 4x4 Front Axle & Wheel Bearing Grease Ford P/N .............................................................................................................................................. ...................................................... E8TZ-19590-A Ford Specification ................................................ ................................................................................................................................... ESA-M1C198-A Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 8530 Wheel Bearing: Service and Repair Wheel Bearing and Wheel Hub Removal and Installation 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 LH rear quarter trim panel. 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. Failure to follow these instructions may result in personal injury. CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. If equipped, turn the air suspension switch to the OFF position. 2. With the vehicle in NEUTRAL, position it on a hoist. 3. NOTE: Have an assistant press the brake pedal to keep the axle from rotating. Remove and discard the rear halfshaft nut and washer. ^ To install, tighten to 300 Nm (221 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 8531 4. Using a suitable hub puller, separate the outboard CV Joint from the wheel hub. 5. CAUTION: Do not allow the caliper to hang from the brake hose or damage to the hose can result. Remove the bolts and position the caliper aside. ^ Support the caliper using mechanic's wire. ^ To install, tighten to 190 Nm (140 ft. lbs.). 6. Remove the brake disc. 7. Disconnect the wheel speed sensor electrical connector and detach the wheel speed sensor harness from the retainer. 8. Remove the bolt and detach the harness from the retainers. To install, tighten the bolt to 15 Nm (11 ft. lbs.). 9. Remove the 4 wheel bearing and hub assembly bolts, the wheel bearing assembly and the wheel speed sensor as an assembly. ^ Route the sensor wiring through the access hole in the brake shield. ^ Discard the bolts. ^ To install, tighten to 185 Nm (136 ft. lbs.). 10. If necessary, remove the wheel speed sensor bolt and the wheel speed sensor from the wheel bearing and hub assembly. ^ To install, tighten to 15 Nm (13 ft. lbs.). 11. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front axle nut ....................................................................................................................................... ...................................................... 27 Nm (20 ft.lbs.) Rear axle wheel hub retainer ........................... ...................................................................................................................................... 345 Nm (254 ft.lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Wheel Hub Lock Solenoid > Component Information > Locations > Page 8539 C1157 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Tighten the wheel nuts, using the pattern indicated, to ............................................................................................................. 204 Nm (150 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 8543 Wheel Fastener: Service and Repair Wheel Studs Special Tools 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 LH rear quarter trim panel. 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. Failure to follow these instructions may result in personal injury. CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Remove the wheel bearing and wheel hub assembly. 2. CAUTION: Never use a hammer to remove a wheel stud. Damage to the wheel hub can result. ^ Place the wheel hub in a soft jawed vice and, using the special tool, remove the wheel stud. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 8544 Installation 1. Position the new wheel stud in the wheel bearing and hub assembly, aligning the serrations in the wheel hub flange made by the original wheel stud. 2. CAUTION: Do not use power tools to install the wheel stud. The serrations on the flange can be stripped. NOTE: Do not use the wheel nut that came with the vehicle. Install 4 washers and a wheel nut on the wheel stud and tighten the wheel nut until the stud seats against the flange. 3. Remove the wheel nut and washers. ^ Discard the wheel nut. 4. Install the wheel bearing and wheel hub assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Temperature Blend Door Actuator, Driver View 151-33 (Climate Control System) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Temperature Blend Door Actuator, Driver > Page 8551 View 151-33 (Climate Control System) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Temperature Blend Door Actuator, Driver > Page 8552 View 151-33 (Climate Control System) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Temperature Blend Door Actuator, Driver > Page 8553 View 151-34 (Auxiliary Climate Control) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Temperature Blend Door Actuator, Driver > Page 8554 View 151-34 (Auxiliary Climate Control) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Blend Door Actuator, Rear C3004 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Blend Door Actuator, Rear > Page 8557 C2091 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Blend Door Actuator, Rear > Page 8558 C2092 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Blend Door Actuator, Rear > Page 8559 C3044 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Blend Door Actuator, Rear > Page 8560 C289 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Auxiliary Temperature Blend Door Actuator Air Door Actuator / Motor: Service and Repair Auxiliary Temperature Blend Door Actuator Air Distribution AUXILIARY TEMPERATURE BLEND DOOR ACTUATOR - AIR DISTRIBUTION Removal and Installation 1. Remove the RH quarter trim panel cup holder and access panel. 2. Remove the 3 auxiliary actuator screws. 3. Disconnect the auxiliary actuator electrical connector. 4. To install, reverse the removal procedure. Temperature AUXILIARY TEMPERATURE BLEND DOOR ACTUATOR - TEMPERATURE Removal and Installation 1. Remove the RH quarter trim panel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Auxiliary Temperature Blend Door Actuator > Page 8563 2. Remove the auxiliary temperature blend door actuator. 1 Disconnect the auxiliary temperature blend door actuator electrical connector. 2 Remove the 4 auxiliary temperature blend door actuator screws. 3 Remove the auxiliary temperature blend door actuator. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Auxiliary Temperature Blend Door Actuator > Page 8564 Air Door Actuator / Motor: Service and Repair Temperature Blend Door Actuator RH TEMPERATURE BLEND DOOR ACTUATOR - RH Removal and Installation 1. Remove the instrument panel. Refer to: Body and Frame, Interior Moulding, Dashboard/Instrument Panel, Service and Repair, Instrument Panel, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel 2. Disconnect the RH temperature blend door actuator electrical connector. 3. Remove the 3 RH temperature blend door actuator screws. 4. Remove the RH temperature blend door actuator. 5. To install, reverse the removal procedure. LH TEMPERATURE BLEND DOOR ACTUATOR - LH Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Auxiliary Temperature Blend Door Actuator > Page 8565 Removal and Installation 1. Remove the heater core and evaporator core housing. 2. Remove the 3 floor duct screws. 3. Remove the floor duct. 4. Disconnect the LH temperature blend door actuator electrical connector. 5. Remove the 3 LH temperature blend door actuator screws. 6. Remove the LH temperature blend door actuator. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Auxiliary Temperature Blend Door Actuator > Page 8566 Air Door Actuator / Motor: Service and Repair Vacuum Control Motor Air Inlet Door VACUUM CONTROL MOTOR - AIR INLET DOOR Removal and Installation 1. Remove the instrument panel. Refer to: Body and Frame, Interior Moulding/Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel 2. Disconnect the air inlet door vacuum control motor vacuum connector. 3. Remove the 2 air inlet door vacuum control motor screws. 4. Remove the air inlet door vacuum control motor. 5. To install, reverse the removal procedure. Floor Defrost Door VACUUM CONTROL MOTOR - FLOOR DEFROST DOOR Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Auxiliary Temperature Blend Door Actuator > Page 8567 Removal and Installation 1. Remove the bolts and position the accelerator pedal aside. - To install, tighten to 25 Nm (18 lb-ft). 2. Disconnect the floor/defrost door vacuum control motor vacuum connector. 3. Remove the 2 floor/defrost door vacuum control motor screws. 4. Rotate the floor/defrost door vacuum control motor until it clears the retaining arm and remove. 5. To install, reverse the removal procedure. Panel Door VACUUM CONTROL MOTOR - PANEL DOOR Removal and Installation 1. Remove the instrument panel. Refer to: Body and Frame, Interior Moulding/Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel 2. Disconnect the panel door vacuum control motor vacuum connector. 3. Remove the 2 panel door vacuum control motor screws. 4. Rotate the panel door vacuum control motor until it clears the retaining arm and remove. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Floor Duct Air Duct: Service and Repair Floor Duct FLOOR DUCT Removal and Installation 1. Remove the heater core and evaporator core housing. 2. Remove the 3 floor duct screws. 3. Remove the floor duct. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Floor Duct > Page 8572 Air Duct: Service and Repair Footwell Duct - Rear FOOTWELL DUCT - REAR Removal and Installation 1. Remove the front seats. 2. Remove the center floor console. 3. NOTE: RH cowl trim and sill plate shown, LH similar. Remove the RH and LH cowl trim panel and sill plates. 4. Fold back the carpet to completely uncover the rear footwell duct. 5. Remove the pin-type retainers and remove the duct. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair Air Register: Service and Repair REGISTER Removal and Installation 1. Fabricate a removal tool from a 3.175 mm (0.12 in) diameter rod. 2. Rotate the register with the removal tool to align the retaining ears with the clearance openings and remove the register. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations View 151-1 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 8579 C132 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 8580 Ambient Temperature Sensor Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 8581 Ambient Temperature Sensor / Switch HVAC: Service and Repair AMBIENT AIR TEMPERATURE SENSOR Removal and Installation Expedition 1. Remove the upper radiator sight shield. All vehicles 2. Detach and disconnect the ambient temperature sensor electrical connector. 3. Remove the ambient air temperature sensor. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Locations View 151-34 (Auxiliary Climate Control) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Locations > Page 8586 C4106 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Locations > Page 8587 Auxiliary Blower Motor: Service and Repair AUXILIARY BLOWER MOTOR Removal and Installation 1. Remove the RH quarter trim panel. 2. Remove the blower motor. 1 Disconnect the blower motor electrical connector. 2 Remove the 4 blower motor screws. 3 Remove the blower motor. 3. Remove the blower motor wheel 1 Remove the push clip. 2 Remove the blower motor wheel. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay Blower Motor Relay: Locations Front Blower Motor Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay > Page 8592 View 151-1 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay > Page 8593 Blower Motor Relay: Locations Rear Blower Motor Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay > Page 8594 View 151-21 (Right Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Front Blower Motor Relay C2216 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Front Blower Motor Relay > Page 8597 C4075 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay Blower Motor Relay: Testing and Inspection Front Blower Motor Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 8600 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 8601 Blower Motor Relay: Testing and Inspection Rear Blower Motor Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 8602 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Auxiliary Blower Motor Resistor Assembly View 151-34 (Auxiliary Climate Control) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Auxiliary Blower Motor Resistor Assembly > Page 8607 View 151-33 (Climate Control System) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Blower Motor Resistor C2185 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Blower Motor Resistor > Page 8610 C4107 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Testing and Inspection > Blower Motor Resistor Blower Motor Resistor Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Testing and Inspection > Blower Motor Resistor > Page 8613 Auxiliary Blower Motor Resistor Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Testing and Inspection > Page 8614 Blower Motor Resistor: Service and Repair AUXILIARY BLOWER MOTOR RESISTOR Removal and Installation 1. Remove the RH quarter trim panel access panel. 2. Remove the blower motor resistor. 1 Disconnect the blower motor resistor electrical connector. 2 Remove the 2 blower motor resistor screws and the blower motor resistor. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Service and Repair > Blower Motor Switch Blower Motor Switch: Service and Repair Blower Motor Switch BLOWER MOTOR SWITCH Removal and Installation 1. Remove the climate control assembly. 2. Pull and remove the blower motor switch knob. 3. Release the 3 clips and remove the blower motor switch. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Service and Repair > Blower Motor Switch > Page 8619 Blower Motor Switch: Service and Repair Blower Motor Speed Control BLOWER MOTOR SPEED CONTROL Removal and Installation 1. Remove the RH lower instrument panel insulator. 2. Disconnect the blower motor speed control electrical connector. 3. Remove the blower motor speed control screw. 4. Remove the blower motor speed control. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair NOTE: The air distribution system of this vehicle cannot be equipped with a cabin air filter. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations View 151-12 (Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Diagrams > In-Vehicle Temperature Sensor C233 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Diagrams > In-Vehicle Temperature Sensor > Page 8628 C2247 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Diagrams > Page 8629 In-Vehicle Temperature Sensor Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > In-Vehicle Temperature Sensor Cabin Temperature Sensor / Switch: Service and Repair In-Vehicle Temperature Sensor IN-VEHICLE TEMPERATURE SENSOR Removal and Installation 1. Remove the instrument cluster finish panel. 2. Disconnect the aspirator hose and the in-vehicle temperature sensor electrical connector. 3. Remove the in-vehicle temperature sensor screws. 4. Remove the in-vehicle temperature sensor. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > In-Vehicle Temperature Sensor > Page 8632 Cabin Temperature Sensor / Switch: Service and Repair In-Vehicle Temperature and Humidity Sensor IN-VEHICLE TEMPERATURE AND HUMIDITY SENSOR Removal and Installation 1. Remove the in-vehicle temperature and humidity sensor trim cover. - Disconnect the electrical connector and aspirator tube. 2. Remove the 2 in-vehicle temperature and humidity sensor screws. 3. Remove the in-vehicle temperature and humidity sensor. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Technical Service Bulletins > Customer Interest for Compressor Clutch: > 08-21-3 > Oct > 08 > A/C Inoperative/Blows Warm Air Compressor Clutch: Customer Interest A/C - Inoperative/Blows Warm Air TSB 08-21-3 10/27/08 A/C SYSTEM BLOWS WARM/INOPERATIVE - HIGH AMBIENT TEMPERATURES, EXTENDED IDLE TIMES, TRAILER TOW, DUSTY CLIMATES OR OFF ROAD USE FORD: 2006 Expedition LINCOLN: 2006 Navigator ISSUE Some 2006 Expedition and Navigator vehicles equipped with A/C may become inoperative or blow warm air due to an open electrical circuit of the A/C compressor field coil in high ambient temperatures, extended idle times, trailer tow, dusty climates or off road use. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Replace the A/C clutch disc, field coil and compressor pulley, using the part numbers below. The replacing parts are larger in diameter. Failure to use the part numbers listed below together may cause repeat failure. 1. Recover A/C refrigerant per Workshop Manual (WSM), Section 412-00. 2. Replace the A/C compressor clutch, field coil and pulley per WSM, Section 412-01. 3. Recharge A/C system per WSM, Section 412-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082103A 2006 Expedition 4X2, 1.4 Hrs. Navigator 4X2/4X4: Replace the A/C compressor clutch, field coil and pulley, Includes Time To Remove and Install Compressor (Do Not Use With 19700A, 19700A4) 082103A 2006 Expedition 4X4: 1.6 Hrs. Replace the A/C compressor clutch, field coil and pulley, Includes Time To Remove and Install Compressor (Do Not Use With 19700A, 19700A4) DEALER CODING CONDITION BASIC PART NO. CODE 19D798 28 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Technical Service Bulletins > Customer Interest for Compressor Clutch: > 08-21-3 > Oct > 08 > A/C Inoperative/Blows Warm Air > Page 8642 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Clutch: > 08-21-3 > Oct > 08 > A/C - Inoperative/Blows Warm Air Compressor Clutch: All Technical Service Bulletins A/C - Inoperative/Blows Warm Air TSB 08-21-3 10/27/08 A/C SYSTEM BLOWS WARM/INOPERATIVE - HIGH AMBIENT TEMPERATURES, EXTENDED IDLE TIMES, TRAILER TOW, DUSTY CLIMATES OR OFF ROAD USE FORD: 2006 Expedition LINCOLN: 2006 Navigator ISSUE Some 2006 Expedition and Navigator vehicles equipped with A/C may become inoperative or blow warm air due to an open electrical circuit of the A/C compressor field coil in high ambient temperatures, extended idle times, trailer tow, dusty climates or off road use. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Replace the A/C clutch disc, field coil and compressor pulley, using the part numbers below. The replacing parts are larger in diameter. Failure to use the part numbers listed below together may cause repeat failure. 1. Recover A/C refrigerant per Workshop Manual (WSM), Section 412-00. 2. Replace the A/C compressor clutch, field coil and pulley per WSM, Section 412-01. 3. Recharge A/C system per WSM, Section 412-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082103A 2006 Expedition 4X2, 1.4 Hrs. Navigator 4X2/4X4: Replace the A/C compressor clutch, field coil and pulley, Includes Time To Remove and Install Compressor (Do Not Use With 19700A, 19700A4) 082103A 2006 Expedition 4X4: 1.6 Hrs. Replace the A/C compressor clutch, field coil and pulley, Includes Time To Remove and Install Compressor (Do Not Use With 19700A, 19700A4) DEALER CODING CONDITION BASIC PART NO. CODE 19D798 28 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Clutch: > 08-21-3 > Oct > 08 > A/C - Inoperative/Blows Warm Air > Page 8648 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Technical Service Bulletins > Page 8649 Compressor Clutch: Specifications Item....................................................................................................................................................... ..............................................................Specification Magnetic Clutch Air gap clearance.................................................................................................................................. ...................................0.35-0.75 mm (0.014-0.030 in) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Technical Service Bulletins > Page 8650 Compressor Clutch: Adjustments AIR CONDITIONING (A/C) CLUTCH AIR GAP ADJUSTMENT 1. Check the A/C clutch air gap at 3 equally spaced places between the clutch plate and the A/C clutch pulley. 2. If the A/C clutch air gap is out of range, remove the clutch plate. Add or remove spacers between the clutch plate hub and the compressor shaft until the clearance is within specification. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Technical Service Bulletins > Page 8651 Compressor Clutch: Service and Repair CLUTCH AND CLUTCH FIELD COIL Special Tool(s) Special Tool(s) Removal 1. Remove the A/C compressor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Technical Service Bulletins > Page 8652 2. Remove the A/C clutch disc and hub nut. 1 Using the special tool, hold the A/C clutch disc and hub. 2 Remove the A/C clutch disc and hub nut. 3. Remove the A/C compressor pulley snap ring. 4. CAUTION: Do not use air tools. Damage to the A/C clutch pulley or A/C compressor may result. Using the special tool, remove the A/C clutch pulley. 5. Remove the A/C clutch field coil snap ring. 6. Remove the A/C clutch field coil. Installation NOTE: The A/C clutch components should be reused unless obvious signs of damage are found. If excessive grooving is found, a new A/C clutch disc and hub and a new A/C compressor pulley must be installed together. Otherwise, each component can be installed individually where needed. 1. Visually inspect the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil for damage. - Inspect for physical damage, including cracked or melted components or discoloration due to excessive heat. - Inspect for excessive wear, including grooving in the A/C clutch disc and hub or A/C compressor pulley that is more than fingernail depth. - Inspect for roughness in the A/C compressor pulley bearing. 2. Clean the A/C clutch field coil and pulley mounting surfaces. 3. Install the A/C clutch field coil. 4. NOTE: The A/C compressor pulley is a tight fit on the A/C compressor. It must be correctly aligned during installation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Technical Service Bulletins > Page 8653 Install the A/C compressor pulley. 1 Install the special tool. 2 Install the A/C compressor pulley. 5. Install the A/C compressor pulley snap ring with the bevel side out. 6. Place one nominal thickness A/C clutch disc and hub spacer inside the clutch hub spline opening. 7. Install the A/C clutch disc and hub. 8. Using the special tool, install the A/C compressor clutch disc and hub nut. 1 Hold the A/C clutch disc and hub with the special tool. 2 Tighten the nut to 20 Nm (15 lb-ft). 9. Measure and adjust the clutch air gap by removing or adding A/C clutch disc and hub spacers. 10. Install the A/C compressor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Technical Service Bulletins > Customer Interest: > 08-21-3 > Oct > 08 > A/C - Inoperative/Blows Warm Air Compressor Clutch Coil: Customer Interest A/C - Inoperative/Blows Warm Air TSB 08-21-3 10/27/08 A/C SYSTEM BLOWS WARM/INOPERATIVE - HIGH AMBIENT TEMPERATURES, EXTENDED IDLE TIMES, TRAILER TOW, DUSTY CLIMATES OR OFF ROAD USE FORD: 2006 Expedition LINCOLN: 2006 Navigator ISSUE Some 2006 Expedition and Navigator vehicles equipped with A/C may become inoperative or blow warm air due to an open electrical circuit of the A/C compressor field coil in high ambient temperatures, extended idle times, trailer tow, dusty climates or off road use. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Replace the A/C clutch disc, field coil and compressor pulley, using the part numbers below. The replacing parts are larger in diameter. Failure to use the part numbers listed below together may cause repeat failure. 1. Recover A/C refrigerant per Workshop Manual (WSM), Section 412-00. 2. Replace the A/C compressor clutch, field coil and pulley per WSM, Section 412-01. 3. Recharge A/C system per WSM, Section 412-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082103A 2006 Expedition 4X2, 1.4 Hrs. Navigator 4X2/4X4: Replace the A/C compressor clutch, field coil and pulley, Includes Time To Remove and Install Compressor (Do Not Use With 19700A, 19700A4) 082103A 2006 Expedition 4X4: 1.6 Hrs. Replace the A/C compressor clutch, field coil and pulley, Includes Time To Remove and Install Compressor (Do Not Use With 19700A, 19700A4) DEALER CODING CONDITION BASIC PART NO. CODE 19D798 28 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Technical Service Bulletins > Customer Interest: > 08-21-3 > Oct > 08 > A/C - Inoperative/Blows Warm Air > Page 8662 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-21-3 > Oct > 08 > A/C - Inoperative/Blows Warm Air Compressor Clutch Coil: All Technical Service Bulletins A/C - Inoperative/Blows Warm Air TSB 08-21-3 10/27/08 A/C SYSTEM BLOWS WARM/INOPERATIVE - HIGH AMBIENT TEMPERATURES, EXTENDED IDLE TIMES, TRAILER TOW, DUSTY CLIMATES OR OFF ROAD USE FORD: 2006 Expedition LINCOLN: 2006 Navigator ISSUE Some 2006 Expedition and Navigator vehicles equipped with A/C may become inoperative or blow warm air due to an open electrical circuit of the A/C compressor field coil in high ambient temperatures, extended idle times, trailer tow, dusty climates or off road use. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Replace the A/C clutch disc, field coil and compressor pulley, using the part numbers below. The replacing parts are larger in diameter. Failure to use the part numbers listed below together may cause repeat failure. 1. Recover A/C refrigerant per Workshop Manual (WSM), Section 412-00. 2. Replace the A/C compressor clutch, field coil and pulley per WSM, Section 412-01. 3. Recharge A/C system per WSM, Section 412-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082103A 2006 Expedition 4X2, 1.4 Hrs. Navigator 4X2/4X4: Replace the A/C compressor clutch, field coil and pulley, Includes Time To Remove and Install Compressor (Do Not Use With 19700A, 19700A4) 082103A 2006 Expedition 4X4: 1.6 Hrs. Replace the A/C compressor clutch, field coil and pulley, Includes Time To Remove and Install Compressor (Do Not Use With 19700A, 19700A4) DEALER CODING CONDITION BASIC PART NO. CODE 19D798 28 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-21-3 > Oct > 08 > A/C - Inoperative/Blows Warm Air > Page 8668 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor Clutch Coil: > 05-22-17 > Nov > 05 > Restraints - Cannot Disable 'Belt Minder' Chime Seat Belt Control Module: All Technical Service Bulletins Restraints - Cannot Disable 'Belt Minder' Chime TSB 05-22-17 11/14/05 INABILITY TO DISABLE THE SUPPLEMENTAL SAFETY BELT WARNING CHIME (BELTMINDER) FORD: 2006 Expedition LINCOLN: 2006 Navigator ISSUE Some 2006 Expedition/Navigator vehicles may exhibit an inability to disable the Belt Minder function following procedures listed in the Workshop Manual or the Owner Guide. The Belt Minder function operates normally, but can not be turned off (if desired by the customer). ACTION Replace the restraint control module (RCM), which includes software to disable the Belt Minder. Refer to Workshop Manual, Section 501-20B to replace the RCM. Then follow Workshop Manual, Section 413-09 or the Owner Guide procedure to disable the Belt Minder function. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052217A 2006 Expedition: Replace 1.0 Hrs. The Restraints Control Module Includes Time To Depower And Repower The Supplemental Restraints System And Disable The Beltminder (Do Not Use With 14056D, 14056D1B, 14056D1C, 14056D1XN, 14056DZR) 052217A 2006 Navigator: Replace 1.2 Hrs. The Restraints Control Module Includes Time To Depower And Repower The Supplemental Restraints System And Disable The Beltminder (Do Not Use With 14056D, 14056D1B, 14056D1C, 14056D1XN, 14056DZR) DEALER CODING CONDITION BASIC PART NO. CODE 14B321 42 OASIS CODES: 104000, 206000 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor Clutch Coil: > 05-22-17 > Nov > 05 > Restraints - Cannot Disable 'Belt Minder' Chime > Page 8674 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor Clutch Coil: > 05-22-17 > Nov > 05 > Restraints - Cannot Disable 'Belt Minder' Chime > Page 8680 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Technical Service Bulletins > Page 8681 C100 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Technical Service Bulletins > Page 8682 Compressor Clutch Coil: Service and Repair CLUTCH AND CLUTCH FIELD COIL Special Tool(s) Special Tool(s) Removal 1. Remove the A/C compressor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Technical Service Bulletins > Page 8683 2. Remove the A/C clutch disc and hub nut. 1 Using the special tool, hold the A/C clutch disc and hub. 2 Remove the A/C clutch disc and hub nut. 3. Remove the A/C compressor pulley snap ring. 4. CAUTION: Do not use air tools. Damage to the A/C clutch pulley or A/C compressor may result. Using the special tool, remove the A/C clutch pulley. 5. Remove the A/C clutch field coil snap ring. 6. Remove the A/C clutch field coil. Installation NOTE: The A/C clutch components should be reused unless obvious signs of damage are found. If excessive grooving is found, a new A/C clutch disc and hub and a new A/C compressor pulley must be installed together. Otherwise, each component can be installed individually where needed. 1. Visually inspect the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil for damage. - Inspect for physical damage, including cracked or melted components or discoloration due to excessive heat. - Inspect for excessive wear, including grooving in the A/C clutch disc and hub or A/C compressor pulley that is more than fingernail depth. - Inspect for roughness in the A/C compressor pulley bearing. 2. Clean the A/C clutch field coil and pulley mounting surfaces. 3. Install the A/C clutch field coil. 4. NOTE: The A/C compressor pulley is a tight fit on the A/C compressor. It must be correctly aligned during installation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Technical Service Bulletins > Page 8684 Install the A/C compressor pulley. 1 Install the special tool. 2 Install the A/C compressor pulley. 5. Install the A/C compressor pulley snap ring with the bevel side out. 6. Place one nominal thickness A/C clutch disc and hub spacer inside the clutch hub spline opening. 7. Install the A/C clutch disc and hub. 8. Using the special tool, install the A/C compressor clutch disc and hub nut. 1 Hold the A/C clutch disc and hub with the special tool. 2 Tighten the nut to 20 Nm (15 lb-ft). 9. Measure and adjust the clutch air gap by removing or adding A/C clutch disc and hub spacers. 10. Install the A/C compressor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Technical Service Bulletins > Customer Interest for Compressor Clutch Hub: > 08-21-3 > Oct > 08 > A/C Inoperative/Blows Warm Air Compressor Clutch Hub: Customer Interest A/C - Inoperative/Blows Warm Air TSB 08-21-3 10/27/08 A/C SYSTEM BLOWS WARM/INOPERATIVE - HIGH AMBIENT TEMPERATURES, EXTENDED IDLE TIMES, TRAILER TOW, DUSTY CLIMATES OR OFF ROAD USE FORD: 2006 Expedition LINCOLN: 2006 Navigator ISSUE Some 2006 Expedition and Navigator vehicles equipped with A/C may become inoperative or blow warm air due to an open electrical circuit of the A/C compressor field coil in high ambient temperatures, extended idle times, trailer tow, dusty climates or off road use. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Replace the A/C clutch disc, field coil and compressor pulley, using the part numbers below. The replacing parts are larger in diameter. Failure to use the part numbers listed below together may cause repeat failure. 1. Recover A/C refrigerant per Workshop Manual (WSM), Section 412-00. 2. Replace the A/C compressor clutch, field coil and pulley per WSM, Section 412-01. 3. Recharge A/C system per WSM, Section 412-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082103A 2006 Expedition 4X2, 1.4 Hrs. Navigator 4X2/4X4: Replace the A/C compressor clutch, field coil and pulley, Includes Time To Remove and Install Compressor (Do Not Use With 19700A, 19700A4) 082103A 2006 Expedition 4X4: 1.6 Hrs. Replace the A/C compressor clutch, field coil and pulley, Includes Time To Remove and Install Compressor (Do Not Use With 19700A, 19700A4) DEALER CODING CONDITION BASIC PART NO. CODE 19D798 28 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Technical Service Bulletins > Customer Interest for Compressor Clutch Hub: > 08-21-3 > Oct > 08 > A/C Inoperative/Blows Warm Air > Page 8693 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Clutch Hub: > 08-21-3 > Oct > 08 > A/C - Inoperative/Blows Warm Air Compressor Clutch Hub: All Technical Service Bulletins A/C - Inoperative/Blows Warm Air TSB 08-21-3 10/27/08 A/C SYSTEM BLOWS WARM/INOPERATIVE - HIGH AMBIENT TEMPERATURES, EXTENDED IDLE TIMES, TRAILER TOW, DUSTY CLIMATES OR OFF ROAD USE FORD: 2006 Expedition LINCOLN: 2006 Navigator ISSUE Some 2006 Expedition and Navigator vehicles equipped with A/C may become inoperative or blow warm air due to an open electrical circuit of the A/C compressor field coil in high ambient temperatures, extended idle times, trailer tow, dusty climates or off road use. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Replace the A/C clutch disc, field coil and compressor pulley, using the part numbers below. The replacing parts are larger in diameter. Failure to use the part numbers listed below together may cause repeat failure. 1. Recover A/C refrigerant per Workshop Manual (WSM), Section 412-00. 2. Replace the A/C compressor clutch, field coil and pulley per WSM, Section 412-01. 3. Recharge A/C system per WSM, Section 412-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082103A 2006 Expedition 4X2, 1.4 Hrs. Navigator 4X2/4X4: Replace the A/C compressor clutch, field coil and pulley, Includes Time To Remove and Install Compressor (Do Not Use With 19700A, 19700A4) 082103A 2006 Expedition 4X4: 1.6 Hrs. Replace the A/C compressor clutch, field coil and pulley, Includes Time To Remove and Install Compressor (Do Not Use With 19700A, 19700A4) DEALER CODING CONDITION BASIC PART NO. CODE 19D798 28 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Clutch Hub: > 08-21-3 > Oct > 08 > A/C - Inoperative/Blows Warm Air > Page 8699 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component Information > Technical Service Bulletins > Customer Interest for Compressor Pulley: > 08-21-3 > Oct > 08 > A/C Inoperative/Blows Warm Air Compressor Pulley: Customer Interest A/C - Inoperative/Blows Warm Air TSB 08-21-3 10/27/08 A/C SYSTEM BLOWS WARM/INOPERATIVE - HIGH AMBIENT TEMPERATURES, EXTENDED IDLE TIMES, TRAILER TOW, DUSTY CLIMATES OR OFF ROAD USE FORD: 2006 Expedition LINCOLN: 2006 Navigator ISSUE Some 2006 Expedition and Navigator vehicles equipped with A/C may become inoperative or blow warm air due to an open electrical circuit of the A/C compressor field coil in high ambient temperatures, extended idle times, trailer tow, dusty climates or off road use. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Replace the A/C clutch disc, field coil and compressor pulley, using the part numbers below. The replacing parts are larger in diameter. Failure to use the part numbers listed below together may cause repeat failure. 1. Recover A/C refrigerant per Workshop Manual (WSM), Section 412-00. 2. Replace the A/C compressor clutch, field coil and pulley per WSM, Section 412-01. 3. Recharge A/C system per WSM, Section 412-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082103A 2006 Expedition 4X2, 1.4 Hrs. Navigator 4X2/4X4: Replace the A/C compressor clutch, field coil and pulley, Includes Time To Remove and Install Compressor (Do Not Use With 19700A, 19700A4) 082103A 2006 Expedition 4X4: 1.6 Hrs. Replace the A/C compressor clutch, field coil and pulley, Includes Time To Remove and Install Compressor (Do Not Use With 19700A, 19700A4) DEALER CODING CONDITION BASIC PART NO. CODE 19D798 28 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component Information > Technical Service Bulletins > Customer Interest for Compressor Pulley: > 08-21-3 > Oct > 08 > A/C Inoperative/Blows Warm Air > Page 8708 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Pulley: > 08-21-3 > Oct > 08 > A/C - Inoperative/Blows Warm Air Compressor Pulley: All Technical Service Bulletins A/C - Inoperative/Blows Warm Air TSB 08-21-3 10/27/08 A/C SYSTEM BLOWS WARM/INOPERATIVE - HIGH AMBIENT TEMPERATURES, EXTENDED IDLE TIMES, TRAILER TOW, DUSTY CLIMATES OR OFF ROAD USE FORD: 2006 Expedition LINCOLN: 2006 Navigator ISSUE Some 2006 Expedition and Navigator vehicles equipped with A/C may become inoperative or blow warm air due to an open electrical circuit of the A/C compressor field coil in high ambient temperatures, extended idle times, trailer tow, dusty climates or off road use. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Replace the A/C clutch disc, field coil and compressor pulley, using the part numbers below. The replacing parts are larger in diameter. Failure to use the part numbers listed below together may cause repeat failure. 1. Recover A/C refrigerant per Workshop Manual (WSM), Section 412-00. 2. Replace the A/C compressor clutch, field coil and pulley per WSM, Section 412-01. 3. Recharge A/C system per WSM, Section 412-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082103A 2006 Expedition 4X2, 1.4 Hrs. Navigator 4X2/4X4: Replace the A/C compressor clutch, field coil and pulley, Includes Time To Remove and Install Compressor (Do Not Use With 19700A, 19700A4) 082103A 2006 Expedition 4X4: 1.6 Hrs. Replace the A/C compressor clutch, field coil and pulley, Includes Time To Remove and Install Compressor (Do Not Use With 19700A, 19700A4) DEALER CODING CONDITION BASIC PART NO. CODE 19D798 28 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Pulley: > 08-21-3 > Oct > 08 > A/C - Inoperative/Blows Warm Air > Page 8714 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Diode HVAC > Component Information > Diagrams C1086 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 8721 View 151-1 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 8722 C1008 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 8723 Compressor Clutch Relay: Description and Operation AIR CONDITIONING (A/C) CLUTCH RELAY (A/CCR) NOTE: The PCM PIDs WAC and wide open throttle air conditioning cutoff fault (WACF) are used to monitor the A/CCR output. The A/CCR (may be referred to as the wide open throttle A/C cutoff [WAC] relay) is wired normally open. There is no direct electrical connection between the A/C switch or EATC module and the A/C clutch. The PCM receives a signal indicating that A/C is requested (for some applications, this message is sent through the communications network). When A/C is requested, the PCM will check other A/C related inputs that are available (such as ACPSW, ACCS). If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant temperature, engine RPM, throttle position), the PCM grounds the A/CCR output, closing the relay contacts and sending voltage to the A/CC. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 8724 Compressor Clutch Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 8725 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Testing and Inspection Condenser HVAC: Testing and Inspection A/C EVAPORATOR/CONDENSER CORE - ON VEHICLE LEAK TEST 1. Recover the refrigerant. 2. NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to the core tubes. Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system. 3. Clean the spring lock couplings. 4. Connect the appropriate test fittings from the R-12/R-134a Air Conditioning Test Fitting Set to the evaporator or condenser tube connections. 5. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to the test fittings. If available, use hoses without shut-off valves. If hoses with shut-off valves are used, make sure the valve opens when attached to the test fittings or install an adapter which will activate the valve. The test is not valid if the shut-off valve does not open. Connect the red and blue hoses from the R-134a Manifold Gauge Set to the test fittings on the A/C evaporator core or A/C condenser core. Connect the yellow hose to a known good vacuum pump. 6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set low pressure gauge indicates 101 kPa (30 in-Hg). The 45 minute evacuation is necessary to remove any refrigerant from oil left in the A/C evaporator core or A/C condenser core. If the refrigerant is not completely removed from the oil, outgassing will degrade the vacuum and appear as a refrigerant leak. 7. If the low pressure gauge reading will not drop to 101 kPa (30 in-Hg) when the valves on the gauge and manifold set are open and the vacuum pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set connections before replacing the 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 very small leak is suspected, wait 30 minutes and observe the vacuum gauge. - If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open for an additional 30 minutes to remove any remaining refrigerant from the oil in the 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Testing and Inspection > Page 8729 Condenser HVAC: Service and Repair CONDENSER CORE Removal and Installation NOTE: Installation of a new receiver/drier is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. 1. Recover the refrigerant. 2. Remove the upper radiator sight shield. 3. Remove the 2 condenser fitting nuts and disconnect the condenser fittings. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 4. Remove the 2 radiator bracket bolts. - To install, tighten to 12 Nm (9 lb-ft). 5. Remove the 2 radiator brackets. 6. Remove the 2 condenser bracket bolts. - To install, tighten to 9 Nm (80 lb-in). 7. Remove the 2 condenser brackets. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Testing and Inspection > Page 8730 8. Remove the condenser core. 9. If a new condenser core is to be installed, transfer the air deflectors from the old unit to the new unit. 10. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 11. Evacuate, leak test and charge the refrigerant system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Auxiliary Function Selector Switch Assembly, Front View 151-23 (Roof) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Auxiliary Function Selector Switch Assembly, Front > Page 8735 View 151-24 (Center Console) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Auxiliary Function Selector Switch Assembly, Front > Page 8736 View 151-12 (Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Auxiliary Function Selector Switch Assembly, Front > Page 8737 View 151-33 (Climate Control System) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions Control Assembly: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8740 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8741 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8742 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8743 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8744 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8745 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8746 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8747 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8748 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8749 Control Assembly: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8750 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8751 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8752 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8753 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8754 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8755 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8756 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8757 Control Assembly: Connector Views C294a C294b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8758 C294c C297 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8759 C989a C989b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 8760 C3198a C3198b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > Function Selector Switch Function Selector Switch Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > Function Selector Switch > Page 8763 Front Auxiliary Climate Control Assembly Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > Function Selector Switch > Page 8764 Rear Auxiliary Climate Control Assembly Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Auxiliary Climate Control Assembly Control Assembly: Service and Repair Auxiliary Climate Control Assembly Front AUXILIARY CLIMATE CONTROL ASSEMBLY - FRONT Removal and Installation All vehicles 1. NOTE: Vehicle with moonroof shown, vehicle without moonroof similar. Disengage the clips and remove the overhead console. Disconnect the electrical connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Auxiliary Climate Control Assembly > Page 8767 Vehicles with moonroof 2. Remove the 4 map light screws. 3. Remove the 2 map lights. All vehicles 4. NOTE: Vehicle with moonroof shown, vehicle without moonroof similar. Remove the 2 front auxiliary climate control assembly screws. 5. Remove the front auxiliary climate control assembly. 6. To install, reverse the removal procedure. Rear AUXILIARY CLIMATE CONTROL ASSEMBLY - REAR Removal and Installation Navigator 1. Open the front floor console cover. 2. Remove the 2 floor console finish panel front screws. 3. Open the rear cup holder and remove the floor console finish panel rear screw. All vehicles 4. NOTE: Navigator shown, Expedition similar. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Auxiliary Climate Control Assembly > Page 8768 Disengage the clips and remove the floor console finish panel. Disconnect the electrical connectors. 5. Remove the 4 rear auxiliary climate control assembly screws. 6. Remove the rear auxiliary climate control assembly. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Auxiliary Climate Control Assembly > Page 8769 Control Assembly: Service and Repair Climate Control Assembly CLIMATE CONTROL ASSEMBLY Removal and Installation 1. Remove the instrument cluster finish panel. 2. Remove the 4 climate control assembly screws. 3. Remove the climate control assembly. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Auxiliary Climate Control Assembly > Page 8770 Control Assembly: Service and Repair Function Selector Switch FUNCTION SELECTOR SWITCH Removal and Installation 1. Remove the climate control assembly. 2. Pull and remove the function selector switch knob. 3. Release the 2 clips and remove the function selector switch. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations View 151-12 (Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > Page 8774 Control Module HVAC: Diagrams C228a Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > Page 8775 C228b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Coupler HVAC: Service and Repair Spring Lock Coupling SPRING LOCK COUPLING Remover, Refrigerant Coupling Spring Special Tool(s) Disconnect 1. Remove the spring lock coupling clip, if equipped. 2. CAUTION: Do not use metal tools to remove the O-ring seals. They can cause axial scratches across the O-ring seal grooves, resulting in refrigerant leaks. Push the tool into the cage opening to release the female fitting from the spring lock coupling spring and pull the fitting apart. Remove the O-ring seals using a non-metallic tool. 3. CAUTION: Do not use a screwdriver or similar tool to remove the A/C tube lock coupling spring; this can cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks. Remove the spring lock coupling spring with a small hooked wire. Cleaning Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling > Page 8780 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. 3. Assemble the pad to the tool. 4. Coat the abrasive pad with mineral oil. 5. Roll the pad on the tool and install it in a variable speed drill motor. 6. CAUTION: Maintain low speed drill rotation when inserting or removing the cleaning tool to prevent axial scratches which may cause future leaks. Polish for one minute at moderate speed (less than 1,500 rpm) or until the surface is clean and free of scratches or foreign material. 7. Clean the fitting with a lint-free cloth. 8. Inspect the surface for grooves or scratches. If grooves and scratches are still present, install a new component. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling > Page 8781 9. Clean the O-ring seal grooves with a 300 mm (12 inch) length of natural fiber string. - Loop the string around the grooves and pull the string back and forth. 10. Remove any foreign material from the grooves with a lint-free cloth. Connect 1. Install the spring lock coupling spring. 2. Lubricate the inside of the coupling with PAG oil. 3. CAUTION: Use only the new O-ring seals. The use of any O-ring seals other than those specified in the Ford Master Parts Catalog may result in intermittent leakage during vehicle operation. Install the O-ring seals. Lubricate the O-ring seals with mineral oil. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling > Page 8782 4. Connect the spring lock coupling fittings with a twisting motion until the spring lock coupling spring snaps over the flared end of the female fitting. 5. Install the spring lock coupling clip. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling > Page 8783 Coupler HVAC: Service and Repair Air Conditioning Line (Peanut) Fitting AIR CONDITIONING LINE (PEANUT) FITTING Disconnect 1. CAUTION: Support the female fitting with a wrench to prevent the tubes from twisting. Remove the nut and separate the 2 halves of the peanut fitting. 2. 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. Remove the O-ring seal with a non-metallic tool. Connect 1. Clean all dirt or foreign material from the fittings. 2. CAUTION: Use only the new O-ring seals. The use of any O-ring seals other than those specified in the Ford Master Parts Catalog may result in intermittent leakage during vehicle operation. Install the O-ring seal. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling > Page 8784 3. NOTE: When correctly assembled, the male and female fittings should be flush. Assemble the male and female fittings together. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Testing and Inspection Evaporator Core: Testing and Inspection A/C EVAPORATOR/CONDENSER CORE - ON VEHICLE LEAK TEST 1. Recover the refrigerant. 2. NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to the core tubes. Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system. 3. Clean the spring lock couplings. 4. Connect the appropriate test fittings from the R-12/R-134a Air Conditioning Test Fitting Set to the evaporator or condenser tube connections. 5. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to the test fittings. If available, use hoses without shut-off valves. If hoses with shut-off valves are used, make sure the valve opens when attached to the test fittings or install an adapter which will activate the valve. The test is not valid if the shut-off valve does not open. Connect the red and blue hoses from the R-134a Manifold Gauge Set to the test fittings on the A/C evaporator core or A/C condenser core. Connect the yellow hose to a known good vacuum pump. 6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set low pressure gauge indicates 101 kPa (30 in-Hg). The 45 minute evacuation is necessary to remove any refrigerant from oil left in the A/C evaporator core or A/C condenser core. If the refrigerant is not completely removed from the oil, outgassing will degrade the vacuum and appear as a refrigerant leak. 7. If the low pressure gauge reading will not drop to 101 kPa (30 in-Hg) when the valves on the gauge and manifold set are open and the vacuum pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set connections before replacing the 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 very small leak is suspected, wait 30 minutes and observe the vacuum gauge. - If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open for an additional 30 minutes to remove any remaining refrigerant from the oil in the 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core Evaporator Core: Service and Repair Evaporator Core EVAPORATOR CORE Removal and Installation NOTE: - If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it is removed from the vehicle. - Installation of a new receiver/drier is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. - A new evaporator core seal is supplied as a kit with the evaporator core service part. Failure to install this seal, or failure to install it correctly, will result in air bypassing the evaporator core and loss of cooling efficiency. 1. Remove the heater core and evaporator core housing. 2. Remove the dash panel seal. 3. Detach the wire harness from the evaporator core cover. 4. Disconnect the air inlet vacuum control motor vacuum connector. 5. Remove the screws and detach the blower motor resistor or blower motor speed control and wire harness from the plenum chamber. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core > Page 8790 6. Remove the 4 bottom evaporator core cover screws. 7. Remove the screws and position the heater core cover aside. 8. Remove the 5 upper evaporator core cover screws. 9. Remove the remaining upper evaporator core cover screws and the evaporator core cover. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core > Page 8791 10. Remove the evaporator core. 11. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Evaporator Core > Page 8792 Evaporator Core: Service and Repair Auxiliary Evaporator Core AUXILIARY EVAPORATOR CORE Removal and Installation NOTE: - If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it is removed from the vehicle. - Installation of a new receiver/drier is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. 1. Remove the auxiliary climate control housing. 2. Disconnect the thermostatic expansion valve (TXV) fittings and remove the TXV. - Discard the O-ring seals. - To install, tighten to 15 Nm (11 lb-ft). 3. Remove the screws and the evaporator/heater core access cover. 4. Remove the evaporator core. 5. To install, reverse the removal procedure. - Install new O-ring seals. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 05-20-7 > Oct > 05 > A/C - Water Leaks Onto Passenger Front Floor Evaporator Drain Tube: Customer Interest A/C - Water Leaks Onto Passenger Front Floor TSB 05-20-7 10/17/05 A/C CONDENSATION LEAKING ONTO THE PASSENGER FRONT FLOOR FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator ISSUE Some 2005-2006 Expedition and Navigator vehicles may exhibit water leaking on to the passenger floor from the NC plenum drain tube area. ACTION Refer to the following Service Procedure to determine if the water leak is from the air conditioning drain tube and repair as necessary. SERVICE PROCEDURE 1. Turn off air suspension, if equipped. 2. Verify the leak is from the HVAC case drain seal and not from another source. Pull back the carpet on the passenger floorboard and feel the HVAC drain tube seal for water (Figure 1A-1B). a. If signs of water or moisture are present continue on with the TSB. b. If there are no signs of water or moisture at the drain tube seal, follow normal diagnosis and repair procedures. 3. Expedition only: Open hood and remove transmission dip stick. 4. Navigator only: Use Message Center to position running boards in the extended position (out setting). Refer to Owners Guide, drivers control Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 05-20-7 > Oct > 05 > A/C - Water Leaks Onto Passenger Front Floor > Page 8801 section for more information. 5. Remove the right front wheel following Workshop Manual, Section 204-04 procedure. 6. Remove right front fender splash shield. 7. Expedition only: Remove transmission dipstick tube from vehicle. 8. Pull back the engine compartment dash panel insulator far enough to expose the HVAC drain tube (Figure 2B) by removing the push pin to the right of the drain (Figure 2A). 9. Push elbow (P/N F3LY-6A614-A) onto drain tube to install. Make sure the short end of the elbow is pushed onto the drain tube, and the long end is pointed straight down (Figure 3). Only water may be used to aid in pushing the elbow onto the drain tube. (Do not use soap or petroleum products on the elbow). 10. Re-seat the engine compartment dash panel insulator and replace the push pin. 11. Expedition only: Install transmission dipstick and tube. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 05-20-7 > Oct > 05 > A/C - Water Leaks Onto Passenger Front Floor > Page 8802 12. Verify the repair by ensuring condensation is dripping outside the vehicle and not running inside onto the passenger floorboard. 13. Replace the right front fender splash shield and wheel. 14. Turn air suspension back on, if equipped. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052007A 2005-2006 Expedition: 0.9 Hr Install Extension On Evaporator Drain (Do not use with 7228A) 052007B 2005-2006 Navigator: 0.7 Hr Install Extension On Evaporator Drain (Do not use with 7228A) DEALER CODING CONDITION BASIC PART NO. CODE 19B739 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 05-20-7 > Oct > 05 > A/C - Water Leaks Onto Passenger Front Floor Evaporator Drain Tube: All Technical Service Bulletins A/C - Water Leaks Onto Passenger Front Floor TSB 05-20-7 10/17/05 A/C CONDENSATION LEAKING ONTO THE PASSENGER FRONT FLOOR FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator ISSUE Some 2005-2006 Expedition and Navigator vehicles may exhibit water leaking on to the passenger floor from the NC plenum drain tube area. ACTION Refer to the following Service Procedure to determine if the water leak is from the air conditioning drain tube and repair as necessary. SERVICE PROCEDURE 1. Turn off air suspension, if equipped. 2. Verify the leak is from the HVAC case drain seal and not from another source. Pull back the carpet on the passenger floorboard and feel the HVAC drain tube seal for water (Figure 1A-1B). a. If signs of water or moisture are present continue on with the TSB. b. If there are no signs of water or moisture at the drain tube seal, follow normal diagnosis and repair procedures. 3. Expedition only: Open hood and remove transmission dip stick. 4. Navigator only: Use Message Center to position running boards in the extended position (out setting). Refer to Owners Guide, drivers control Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 05-20-7 > Oct > 05 > A/C - Water Leaks Onto Passenger Front Floor > Page 8808 section for more information. 5. Remove the right front wheel following Workshop Manual, Section 204-04 procedure. 6. Remove right front fender splash shield. 7. Expedition only: Remove transmission dipstick tube from vehicle. 8. Pull back the engine compartment dash panel insulator far enough to expose the HVAC drain tube (Figure 2B) by removing the push pin to the right of the drain (Figure 2A). 9. Push elbow (P/N F3LY-6A614-A) onto drain tube to install. Make sure the short end of the elbow is pushed onto the drain tube, and the long end is pointed straight down (Figure 3). Only water may be used to aid in pushing the elbow onto the drain tube. (Do not use soap or petroleum products on the elbow). 10. Re-seat the engine compartment dash panel insulator and replace the push pin. 11. Expedition only: Install transmission dipstick and tube. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 05-20-7 > Oct > 05 > A/C - Water Leaks Onto Passenger Front Floor > Page 8809 12. Verify the repair by ensuring condensation is dripping outside the vehicle and not running inside onto the passenger floorboard. 13. Replace the right front fender splash shield and wheel. 14. Turn air suspension back on, if equipped. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052007A 2005-2006 Expedition: 0.9 Hr Install Extension On Evaporator Drain (Do not use with 7228A) 052007B 2005-2006 Navigator: 0.7 Hr Install Extension On Evaporator Drain (Do not use with 7228A) DEALER CODING CONDITION BASIC PART NO. CODE 19B739 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation Evaporator Temperature Sensor / Switch: Description and Operation AIR CONDITIONING EVAPORATOR TEMPERATURE (ACET) SENSOR A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance The ACET sensor measures the evaporator air discharge temperature. The ACET sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The PCM sources a low current 5 volts on the ACET circuit. With SIG RTN also connected to the ACET sensor, the varying resistance affects the voltage drop across the sensor terminals. As A/C evaporator air temperature changes, the varying resistance of the ACET sensor changes the voltage the PCM detects. The ACET sensor is used to more accurately control A/C clutch cycling, improve defrost/demist performance, and reduce A/C clutch cycling. NOTE: These values can vary 15 percent due to sensor and VREF variations. Voltage values were calculated for VREF equals 5.0 volts. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Page 8813 Evaporator Temperature Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) EVAPORATOR DISCHARGE AIR TEMPERATURE SENSOR Removal and Installation 1. Lower the glove compartment. 2. Remove the evaporator discharge air temperature sensor screw. 3. Disconnect the evaporator discharge air temperature sensor electrical connector. 4. Carefully pry the evaporator discharge air temperature sensor probe out of the heater core and evaporator core housing. 5. Remove the evaporator discharge air temperature sensor. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 06-10-4 > May > 06 > A/C - Rear A/C Hoot/Whistle Noise Expansion Valve: Customer Interest A/C - Rear A/C Hoot/Whistle Noise TSB 06-10-4 05/29/06 HOOT OR WHISTLE NOISE FROM REAR A/C SYSTEM FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-21-1 to add a production fix date. ISSUE Some 2005-2006 Expedition/Navigator vehicles built before 1/30/2006 may exhibit a hoot or whistle noise inside the passenger compartment, coming from the rear auxiliary A/C system. The noise will most likely be heard by the customer when driving the vehicle with the interior cooled down, the rear A/C off, front A/C on, and the blower fan on the low speed setting. ACTION Replace the thermostatic expansion valve (TXV), located near the rear auxiliary A/C housing, following the Workshop Manual procedure (Removal And Installation: Thermostatic Expansion Valve). The procedure can be found in Section 412-03B of the 2005 MY Workshop Manual, or Section 412-02 of the 2006 MY Workshop Manual. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061004A 2005-2006 1.7 Expedition/Navigator: Hrs. Replace The Thermostatic Expansion Valve Includes Time To Verify Concern, Recover, Evacuate, Re- Charge Air Conditioning System: (Do not use with 19700A, 19700AZU, 19700A13) DEALER CODING CONDITION BASIC PART NO. CODE 19849 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 06-10-4 > May > 06 > A/C - Rear A/C Hoot/Whistle Noise Expansion Valve: All Technical Service Bulletins A/C - Rear A/C Hoot/Whistle Noise TSB 06-10-4 05/29/06 HOOT OR WHISTLE NOISE FROM REAR A/C SYSTEM FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-21-1 to add a production fix date. ISSUE Some 2005-2006 Expedition/Navigator vehicles built before 1/30/2006 may exhibit a hoot or whistle noise inside the passenger compartment, coming from the rear auxiliary A/C system. The noise will most likely be heard by the customer when driving the vehicle with the interior cooled down, the rear A/C off, front A/C on, and the blower fan on the low speed setting. ACTION Replace the thermostatic expansion valve (TXV), located near the rear auxiliary A/C housing, following the Workshop Manual procedure (Removal And Installation: Thermostatic Expansion Valve). The procedure can be found in Section 412-03B of the 2005 MY Workshop Manual, or Section 412-02 of the 2006 MY Workshop Manual. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061004A 2005-2006 1.7 Expedition/Navigator: Hrs. Replace The Thermostatic Expansion Valve Includes Time To Verify Concern, Recover, Evacuate, Re- Charge Air Conditioning System: (Do not use with 19700A, 19700AZU, 19700A13) DEALER CODING CONDITION BASIC PART NO. CODE 19849 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > Climate Control Expansion Valve: Service and Repair Climate Control Thermostatic Expansion Valve THERMOSTATIC EXPANSION VALVE Removal and Installation NOTE: Installation of a new receiver/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 receiver/drier. 1. Recover the refrigerant. 2. Remove the powertrain control module (PCM) and PCM bracket. 3. Remove the thermostatic expansion valve (TXV) fitting bolt. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 4. Remove the 2 bolts and the thermostatic expansion valve. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 5. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 6. Evacuate, leak test and charge the refrigerant system. Thermostatic Expansion Valve Manifold and Tube Assembly THERMOSTATIC EXPANSION VALVE MANIFOLD AND TUBE ASSEMBLY Removal and Installation NOTE: Installation of a new receiver/drier is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. 1. Recover the refrigerant. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > Climate Control > Page 8829 2. Remove the nut and disconnect the A/C fitting. - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). 3. Remove the nut and disconnect the A/C fitting. - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). 4. Remove the 2 bolts and the thermostatic expansion valve (TXV) manifold and tube assembly. - To install, tighten to 8 Nm (71 lb-in). 5. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 6. Evacuate, leak test and charge the refrigerant system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > Climate Control > Page 8830 Expansion Valve: Service and Repair Auxiliary Climate Control THERMOSTATIC EXPANSION VALVE Removal and Installation 1. Recover the refrigerant. 2. Remove the RH quarter trim panel. 3. Disconnect the fittings and remove the thermostatic expansion valve. - Discard the O-ring seals. 4. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 5. Evacuate, leak test and charge the refrigerant system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest: > 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8839 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8840 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8846 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8847 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 09-20-14 > Oct > 09 > A/T - Uncommanded TCC Lock Up On 1-2 Upshift Torque Converter Clutch: All Technical Service Bulletins A/T - Uncommanded TCC Lock Up On 1-2 Upshift TSB 09-20-14 10/19/09 UN-COMMANDED TCC APPLY ON THE 1-2 SHIFT CAUSING PERCEPTION OF HESITATION AND/OR LACK OF POWER DURING SHIFT FORD: 2005-2010 Crown Victoria 2005-2006 Expedition 2005-2010 E-150, E-250, E-350, F-150 LINCOLN: 2005-2010 Town Car 2006-2008 Mark LT MERCURY: 2005-2010 Grand Marquis This article supersedes TSB 6-22-7 to update the Issue Statement, vehicle model years and model line covered. ISSUE Some 2005-2010 vehicles equipped with a 4R70/75E-W transmission may experience an un-commanded torque converter clutch (TCC) apply or TCC partial apply immediately after the 1-2 shift. This may result in the perception that the vehicle lacks power or that the transmission is up-shifting too early. Additional symptoms of uncommanded TCC apply when coming to a stop (before the 2-1 downshift is commanded), are engine stalling or lugging when engaging manual 2nd while at a stop and code P1742 may be present in continuous memory. However, the vehicle should operate normally in park, reverse, neutral and manual 1st gear. ACTION Follow the Service Procedure for verification and repair. SERVICE PROCEDURE 1. Monitor (TCC %) solenoid command state - duty cycle and (TC SLIP ACT) torque converter clutch slippage - RPM, while in 2nd, 3rd or 4th gear with a TCC % reading 0. a. If TCC % = 0 and TC SLIP ACT = less than 20 RPM then inspect the number 7 check ball in the main control valve body for damage. Replace as required following the appropriate Workshop Manual (WSM) under Disassembly and Assembly of Subassemblies - Main Control Valve Body. (Figure 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 09-20-14 > Oct > 09 > A/T - Uncommanded TCC Lock Up On 1-2 Upshift > Page 8853 NOTE THIS PROCEDURE IS PERFORMED IN 2ND GEAR AUTO (NOT MANUAL 2). MONITOR (TC SLIP ACT) AFTER THE POWERTRAIN CONTROL MODULE (PCM) COMMANDS 2ND GEAR AND BEFORE THE VEHICLE SPEED SENSOR (VSS) READS 35 MPH (56 KM/H). b. If you receive any other reading, this procedure does not apply; follow normal diagnostic procedures as outlined in the appropriate WSM. NOTE IT IS NORMAL FOR THE PCM TO COMMAND 4TH GEAR AT SPEEDS AS LOW AS 19 MPH (30 KM/H) WITH LIGHT ACCELERATION WHEN THE THROTTLE POSITION IS LESS THEN 20%. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092014A 2005-2010 Crown Victoria, 2.3 Hrs. Grand Marquis, Town Car, Econoline 150/250/350, 2005-2006 Expedition: Includes Time To Perform The Diagnosis Outlined In This Article And Repair (Do Not Use With Any Other Labor Operations) 092014A 2005-2010 F-150, 2.2 Hrs. 2006-2008 Mark LT: Includes Time To Perform The Diagnosis Outlined In This Article And Repair (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7E195 01 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 09-20-14 > Oct > 09 > A/T - Uncommanded TCC Lock Up On 1-2 Upshift > Page 8859 NOTE THIS PROCEDURE IS PERFORMED IN 2ND GEAR AUTO (NOT MANUAL 2). MONITOR (TC SLIP ACT) AFTER THE POWERTRAIN CONTROL MODULE (PCM) COMMANDS 2ND GEAR AND BEFORE THE VEHICLE SPEED SENSOR (VSS) READS 35 MPH (56 KM/H). b. If you receive any other reading, this procedure does not apply; follow normal diagnostic procedures as outlined in the appropriate WSM. NOTE IT IS NORMAL FOR THE PCM TO COMMAND 4TH GEAR AT SPEEDS AS LOW AS 19 MPH (30 KM/H) WITH LIGHT ACCELERATION WHEN THE THROTTLE POSITION IS LESS THEN 20%. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 092014A 2005-2010 Crown Victoria, 2.3 Hrs. Grand Marquis, Town Car, Econoline 150/250/350, 2005-2006 Expedition: Includes Time To Perform The Diagnosis Outlined In This Article And Repair (Do Not Use With Any Other Labor Operations) 092014A 2005-2010 F-150, 2.2 Hrs. 2006-2008 Mark LT: Includes Time To Perform The Diagnosis Outlined In This Article And Repair (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7E195 01 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 8860 Heater Core: Testing and Inspection HEATER CORE 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. 1. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores were good and did not require replacement. If a heater core leak is suspected, the heater core must be tested by carrying out the plugged heater core component test before the heater core pressure test. Carry out a system inspection by checking the heater system thoroughly as follows: Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater water hose could follow the heater core tube to the heater core and appear as a leak in the heater core. 2. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of non-specification clamps can cause leakage at the heater water hose connection and damage the heater core. Check the integrity of the heater water hose clamps. 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 correct 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 is not working correctly. Heater Core - Pressure Test Use the Radiator/Heater Core Pressure Tester to perform the pressure test. 1. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. Drain the coolant from the cooling system. 2. Disconnect the heater 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 138 kPa (20 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of 3 minutes. 8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, remove the heater core from the vehicle and perform the bench test. Heater Core - Bench Test 1. Remove the heater core from the vehicle. 2. Drain all of the coolant from the heater core. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 8861 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 138 kPa (20 psi) of air pressure to the heater core. Submerge the heater core in water. 5. If a leak is observed, install a new heater core. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core Heater Core: Service and Repair Heater Core HEATER CORE Removal and Installation NOTE: If a heater core leak is suspected, the heater core must be leak tested before it is removed from the vehicle. 1. Remove the heater core and evaporator core housing. 2. Remove the dash panel seal. 3. Remove the 3 temperature blend door actuator screws. 4. Remove the temperature blend door actuator. 5. Remove the 4 heater core cover screws. 6. Remove the heater core cover. 7. Remove the heater core. 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core > Page 8864 Heater Core: Service and Repair Auxiliary Heater Core AUXILIARY HEATER CORE Removal and Installation 1. Remove the auxiliary climate control housing. 2. Remove the screws and the evaporator/heater core access cover. 3. Remove the heater core. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Service and Repair Heater Core Case: Service and Repair HEATER CORE AND EVAPORATOR CORE HOUSING Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Service and Repair > Page 8868 Part 2 Removal and Installation NOTE: - If an evaporator core leak is suspected, the evaporator must be vacuum leak tested before it is removed from the vehicle. - Installation of a new receiver/drier is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. 1. Recover the refrigerant. 2. Drain the engine coolant. 3. Remove the instrument panel. Refer to: Body and Frame, Interior Moulding/Trim, Dashboard/Instrument Panel, Service and Repair, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 4. Remove the rear footwell duct. 5. Remove the powertrain control module (PCM) and PCM bracket. 6. Disconnect the 2 heater hose quick-disconnect fittings at the heater core. 7. Remove the bolt and detach the thermostatic expansion valve (TXV). - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 8. Disconnect the evaporator outlet fitting. - Discard the O-ring seals. 9. Disconnect the evaporator inlet fitting. - Discard the O-ring seals. 10. Remove the thermostatic expansion valve bracket nut. - To install, tighten to 5 Nm (44 lb-in). 11. Remove the 3 heater core and evaporator core housing nuts. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Service and Repair > Page 8869 - To install, tighten to 5 Nm (44 lb-in). 12. Disconnect the 2 vacuum lines at the top of the heater core and evaporator core housing. 13. Detach the wire harness connectors from the bracket below the air inlet duct. 14. Remove the air inlet duct bracket nut. - To install, tighten to 7 Nm (62 lb-in). 15. Remove the plenum chamber nut. - To install, tighten to 5 Nm (44 lb-in). 16. Remove the heater core and evaporator core housing. 17. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. - Clean and lubricate the coolant hoses with plain water only if needed. 18. Fill the engine coolant level. 19. Evacuate, leak test and charge the refrigerant system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 (V8-5.4L VIN 5 (2006)) 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 8878 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 (V8-5.4L VIN 5 (2006)) 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 8879 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 (V8-5.4L VIN 5 (2006)) 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 (V8-5.4L VIN 5 (2006)) 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 8885 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 (V8-5.4L VIN 5 (2006)) 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 8886 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hose Coupling Heater Hose: Service and Repair Heater Hose Coupling HEATER HOSE COUPLING Remover, Heater Hose Inlet Tube Special Tool(s) Disconnect 1. 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. Depressurize the engine cooling system. 2. Push the heater water hose toward the tube to fully expose the locking tabs. 3. NOTE: When compressing the white coupling retainer, the Heater Hose Disconnect Tool must be perpendicular to and on the highest point of the coupling. Push the special tool over the coupling retainer windows to compress the retainer locking tabs. 4. NOTE: A slight twisting motion while pulling on the heater water hose may be necessary to assist in the removal. Pull the heater water hose away from the heater core tube. 5. Plug the heater water hose. 6. Remove the white coupling retainer from the tube. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hose Coupling > Page 8889 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 MERPOL(R) meeting Ford specification ESE-M99B144-B or plain water. 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hose Coupling > Page 8890 Heater Hose: Service and Repair Auxiliary Heater Outlet and Inlet Line AUXILIARY HEATER OUTLET AND INLET LINE Removal CAUTION: To avoid refrigerant loss, clearly differentiate the auxiliary heater lines from the auxiliary refrigerant lines before beginning this procedure. NOTE: - The auxiliary heater inlet and outlet lines are not supplied together as an assembly. The auxiliary heater inlet line and outlet line are each installed from the factory as 1-piece assemblies. The replacement parts are supplied as separate kits containing multiple piece lines for ease of installation. - The following procedure can be used to remove and install 1 or both the auxiliary heater inlet and auxiliary heater outlet lines. If only one auxiliary heater line is to be removed and installed, cut or disconnect only the desired line at the specified points within the procedure. 1. Drain the engine coolant. 2. Remove the RH quarter trim panel. 3. Detach the auxiliary heater lines. 1 Disconnect the heater hose(s). 2 Remove the 2 line bracket bolts. 3 Remove the line bracket. 4. Remove the spare tire. 5. Raise the vehicle. 6. Remove the RH front wheel. 7. Remove the RH fender splash shield. 8. NOTE: If installing only one auxiliary heater line, disconnect only the desired line. Disconnect the heater hose(s). 9. Remove the muffler. 10. Remove the RH catalytic converter. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hose Coupling > Page 8891 11. Remove the 3 bolts and the heat shield. 12. Remove the bolts. 13. Remove the nut and the line bracket. 14. Remove the bolt and the heat shield. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hose Coupling > Page 8892 15. Remove the nuts and the remaining line brackets. 16. NOTE: If installing only one auxiliary heater line, cut only the desired line. Assemble and lay out the replacement line(s) in the same position as the existing line(s) and, using a suitable tool, cut the auxiliary heater line(s) in the same position as the fittings on the new line(s). 17. Remove the auxiliary heater line(s) in 3 separate pieces. Installation 1. Partially lower the vehicle. 2. Attach the rear portion of the auxiliary heater lines. 1 Connect the heater hoses. 2 Install the line bracket. 3 Install the bolts. 3. Install the front auxiliary heater line(s) and connect the heater hose(s). - Clean and lubricate the heater hoses with plain water only if needed. 4. Raise the vehicle. 5. NOTE: Loosely connect, but do not tighten, the fittings. Install the middle auxiliary heater line(s). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hose Coupling > Page 8893 6. Starting from the rear of the vehicle, install the first 3 line brackets. - Tighten to 5 Nm (44 lb-in). 7. Tighten the middle auxiliary heater line fittings. 8. Inspect the auxiliary heater lines for correct installation. Loosen, reposition and tighten as needed. 9. Install the heat shield and the bolts. - Tighten to 15 Nm (11 lb-ft). 10. Install the heat shield and the bolts. - Tighten to 15 Nm (11 lb-ft). 11. Install the RH catalytic converter. 12. Install the muffler. 13. Partially lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hose Coupling > Page 8894 14. Install the heat shield bolt. - Tighten to 15 Nm (11 lb-ft). 15. Install the line bracket. - Tighten to 5 Nm (44 lb-in). 16. Lower the vehicle. 17. Install the spare tire. 18. Install the RH quarter trim panel. 19. Fill the engine coolant level. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly Hose/Line HVAC: Service and Repair Compressor Manifold and Tube Assembly COMPRESSOR MANIFOLD AND TUBE ASSEMBLY Removal and Installation NOTE: Installation of a new receiver/drier is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. All vehicles 1. Recover the refrigerant. 2. Disconnect the negative and positive battery cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 8899 3. Disconnect the electrical connector. 4. Disconnect the pressure cutoff switch electrical connector. 5. Remove the compressor manifold and tube suction fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). Vehicles with auxiliary A/C 6. Remove the auxiliary evaporator outlet line fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). All vehicles 7. Remove the compressor manifold and tube assembly discharge fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). 8. Loosen the compressor manifold bolt and remove the compressor manifold and tube assembly. - Discard the O-ring seals. - To install, tighten to 20 Nm (15 lb-ft). 9. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 10. Evacuate, leak test and charge the refrigerant system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 8900 Hose/Line HVAC: Service and Repair Auxiliary Evaporator Outlet and Inlet Line AUXILIARY EVAPORATOR OUTLET AND INLET LINE Removal NOTE: - The auxiliary evaporator inlet and outlet lines are not supplied together as an assembly. The auxiliary evaporator inlet line and outlet line are each installed from the factory as 1-piece assemblies. The replacement parts are supplied as separate kits containing multiple piece lines for ease of installation. - The following procedure can be used to remove and install 1 or both the auxiliary evaporator inlet and auxiliary evaporator outlet lines. If only one auxiliary evaporator line is to be removed and installed, cut or disconnect only the desired line at the specified points within the procedure. - Installation of a new receiver/drier is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. 1. Recover the refrigerant. 2. NOTE: If only one auxiliary evaporator line is to be removed, disconnect only the desired line. Remove the nut(s) and disconnect the A/C fitting(s). 3. Remove the RH quarter trim panel. 4. Remove the spare tire. 5. NOTE: Both A/C fittings must be disconnected even if only one line is to be removed. Disconnect the A/C fittings. Install new O-rings seals. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 8901 6. Remove the bolts and the line bracket. 7. Raise the vehicle. 8. Remove the spare tire carrier splash shield. 9. Remove the RH front wheel. 10. Remove the RH fender splash shield. 11. Remove the muffler. 12. Remove the RH catalytic converter. 13. Remove the 3 bolts and the heat shield. 14. Remove the bolts. 15. Remove the nut and the line bracket. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 8902 16. Remove the bolt and the heat shield. 17. Remove the nuts and the remaining line brackets. 18. NOTE: If installing only one auxiliary evaporator line, cut only the desired line. Assemble and lay out the replacement line(s) in the same position as the existing line(s) and, using a suitable tool, cut the auxiliary evaporator line(s) in the same position as the fittings on the new line(s). 19. Remove the auxiliary evaporator line(s) in 3 separate pieces. Installation 1. Partially lower the vehicle to allow access to both the rear auxiliary line fittings and the underside of the vehicle. 2. Position the rear portion of the auxiliary evaporator line(s) and install the line bracket and bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 8903 3. Connect the A/C fittings. - Install new O-ring seals. - Tighten to 8 Nm (71 lb-in). 4. Install the front auxiliary evaporator line(s) and connect the A/C fittings. - Install new O-ring seals. - Tighten to 8 Nm (71 lb-in). 5. Raise the vehicle. 6. NOTE: Loosely connect, but do not tighten, the fittings. Install the middle auxiliary evaporator line(s). 7. Starting from the rear of the vehicle, install the first 3 line brackets. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 8904 - Tighten to 5 Nm (44 lb-in). 8. Tighten the middle auxiliary evaporator line fittings. 9. Inspect the auxiliary evaporator lines for correct installation. Loosen, reposition and tighten as needed. 10. Install the heat shield and the bolts. - Tighten to 15 Nm (11 lb-ft). 11. Install the heat shield and the bolts. - Tighten to 15 Nm (11 lb-ft). 12. Install the RH catalytic converter. 13. Install the muffler. 14. Partially lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Manifold and Tube Assembly > Page 8905 15. Install the heat shield bolt. - To install, tighten to 15 Nm (11 lb-ft). 16. Install the line bracket. - Tighten to 5 Nm (44 lb-in). 17. Install the spare tire carrier splash shield. 18. Install the RH front fender splash shield. 19. Install the RH front wheel. 20. Lower the vehicle. 21. Install the RH quarter trim panel. 22. Install the spare tire. 23. Lubricate the refrigerant system with the correct amount of clean PAG oil. 24. Evacuate, leak test and charge the refrigerant system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Plenum Chamber Housing Assembly HVAC: Service and Repair Plenum Chamber PLENUM CHAMBER Removal and Installation 1. Remove the heater core and evaporator core housing. 2. Disconnect the 2 plenum chamber vacuum connectors and position the vacuum harness aside. 3. Remove the 3 upper plenum chamber screws. 4. Remove the 5 lower plenum chamber screws. 5. Remove the plenum chamber. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Plenum Chamber > Page 8910 Housing Assembly HVAC: Service and Repair Heater Core and Evaporator Core Housing HEATER CORE AND EVAPORATOR CORE HOUSING Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Plenum Chamber > Page 8911 Part 2 Removal and Installation NOTE: - If an evaporator core leak is suspected, the evaporator must be vacuum leak tested before it is removed from the vehicle. - Installation of a new receiver/drier is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. 1. Recover the refrigerant. 2. Drain the engine coolant. 3. Remove the instrument panel. Refer to: Body and Frame, Interior Moulding/Trim, Dashboard/Instrument Panel, Service and Repair, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 4. Remove the rear footwell duct. 5. Remove the powertrain control module (PCM) and PCM bracket. 6. Disconnect the 2 heater hose quick-disconnect fittings at the heater core. 7. Remove the bolt and detach the thermostatic expansion valve (TXV). - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 8. Disconnect the evaporator outlet fitting. - Discard the O-ring seals. 9. Disconnect the evaporator inlet fitting. - Discard the O-ring seals. 10. Remove the thermostatic expansion valve bracket nut. - To install, tighten to 5 Nm (44 lb-in). 11. Remove the 3 heater core and evaporator core housing nuts. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Plenum Chamber > Page 8912 - To install, tighten to 5 Nm (44 lb-in). 12. Disconnect the 2 vacuum lines at the top of the heater core and evaporator core housing. 13. Detach the wire harness connectors from the bracket below the air inlet duct. 14. Remove the air inlet duct bracket nut. - To install, tighten to 7 Nm (62 lb-in). 15. Remove the plenum chamber nut. - To install, tighten to 5 Nm (44 lb-in). 16. Remove the heater core and evaporator core housing. 17. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. - Clean and lubricate the coolant hoses with plain water only if needed. 18. Fill the engine coolant level. 19. Evacuate, leak test and charge the refrigerant system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Plenum Chamber > Page 8913 Housing Assembly HVAC: Service and Repair Auxiliary Climate Control Housing AUXILIARY CLIMATE CONTROL HOUSING Removal and Installation 1. Recover the refrigerant. 2. Drain the engine cooling system. 3. Remove the RH quarter trim panel. Refer to: Body and Frame, Interior Moulding/Trim, Trim Panel, Service and Repair, See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair 4. Detach the upper air duct from the auxiliary housing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Plenum Chamber > Page 8914 5. Remove the nuts and disconnect the auxiliary evaporator line fittings. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 6. Remove the bolts and the auxiliary line bracket. 7. Disconnect the heater hoses. 1 Using suitable tools, clamp off the heater hoses to prevent residual coolant from spilling into the vehicle. 2 Disconnect the heater hoses. 8. Disconnect the drain hose. 9. Disconnect the blower motor electrical connector. 10. Disconnect the blower motor resistor electrical connector. 11. Disconnect the auxiliary temperature blend door actuator electrical connector. 12. Disconnect the auxiliary mode door actuator electrical connector. 13. Remove the 2 auxiliary climate control housing bolts. 14. Remove auxiliary climate control housing. 15. To install, reverse the removal procedure. - Install new O-ring seals. - Clean and lubricate the coolant hoses with plain water only if needed. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 16. Fill the engine coolant level. 17. Evacuate, leak test and charge the refrigerant system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Humidity Sensor > Component Information > Diagrams C2247 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Humidity Sensor > Component Information > Diagrams > Page 8918 Humidity Sensor: Service and Repair IN-VEHICLE TEMPERATURE AND HUMIDITY SENSOR Removal and Installation 1. Remove the in-vehicle temperature and humidity sensor trim cover. - Disconnect the electrical connector and aspirator tube. 2. Remove the 2 in-vehicle temperature and humidity sensor screws. 3. Remove the in-vehicle temperature and humidity sensor. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Service and Repair Receiver Dryer: Service and Repair RECEIVER DRIER Removal and Installation NOTE: Installation of a new receiver/drier is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier. All vehicles 1. Recover the refrigerant. 2. Remove the condenser outlet fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). 3. Remove the receiver/drier outlet fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). Vehicles with auxiliary A/C 4. Remove the auxiliary evaporator inlet line fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). All vehicles 5. Remove the receiver/drier bracket nut. - To install, tighten to 12 Nm (9 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Service and Repair > Page 8922 6. Detach the bracket and remove the receiver/drier. 7. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 8. Evacuate, leak test and charge the refrigerant system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Item....................................................................................................................................................... ..............................................................Specification Refrigerant and Capacity Capacity without auxiliary climate control............................................................................................. ..........................................................1.13 kg (40 oz) Capacity with auxiliary climate control............... .............................................................................................................................................1.64 kg (58 oz) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 8927 Refrigerant: Fluid Type Specifications REFRIGERANT TYPE R134a Refrigerant Ford P/N .............................................................................................................................................. ..................................................................... YN-19 Ford Specification ............................................... .................................................................................................................................... WSH-M17B19-A Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 8928 Refrigerant: Description and Operation REFRIGERANT SYSTEM DYE Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in refrigerant system leak diagnosis using a Rotunda-approved ultraviolet blacklight. It is not necessary to add additional dye to the refrigerant system before diagnosing leaks, even if a significant amount of refrigerant has been removed from the system. New suction accumulators are shipped with a fluorescent dye "wafer" included in the desiccant bag which will dissolve after approximately 30 minutes of continued A/C operation. It is not necessary to add dye after flushing or filtering the refrigerant system because a new suction accumulator is installed as part of the flushing or filtering procedure. Additional refrigerant system dye should only be added if more than 50% of the refrigerant system lubricant capacity has been lost due to a fitting separation, hose rupture or other damage. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Testing and Inspection > Fluorescent Dye Leak Detection Refrigerant: Testing and Inspection Fluorescent Dye Leak Detection FLUORESCENT DYE LEAK DETECTION Special Tool(s) Special Tool(s) Fluorescent Dye Detection NOTE: Ford Motor Company vehicles are produced with R-134a fluorescent dye installed in the refrigerant system from the factory. The location of leaks can be pinpointed by the bright yellow-green glow of the fluorescent dye under a UV lamp. Since more than one leak can exist, make sure to inspect each component, line and fitting in the refrigerant system for a leak. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Testing and Inspection > Fluorescent Dye Leak Detection > Page 8931 1. Check for leaks using a Rotunda-approved UV lamp. - Inspect all components, lines and fittings of the refrigerant system. 2. If a leak is found, recover the refrigerant. 3. Repair the refrigerant system leak(s). 4. Evacuate and charge the refrigerant system. 5. After the leak(s) is/are repaired, remove any traces of fluorescent dye with a general purpose oil solvent. 6. Verify the repair by running the vehicle for a short period of time and rechecking the area of the leak with a Rotunda-approved UV lamp. Fluorescent Dye Injection - Using an A/C Refrigerant Center and Dye Injector NOTE: - Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in refrigerant system leak diagnosis using a Rotunda-approved ultraviolet blacklight. It is not necessary to add additional dye to the refrigerant system before diagnosing leaks, even if a significant amount of refrigerant has been removed from the system. Replacement suction accumulators and receiver/driers are shipped with a fluorescent dye "wafer" included in the desiccant bag which will dissolve after approximately 30 minutes of continued A/C operation. It is not necessary to add dye after flushing or filtering the refrigerant system because a new suction accumulator or receiver/drier is installed as part of the flushing or filtering procedure. Additional refrigerant system dye should only be added if more than 50% of the refrigerant system lubricant capacity has been lost due to a fitting separation, hose rupture or other damage. - Before using the R-134a fluorescent dye injector for the first time, refer to the manufacturers instructions on evacuation of any non-condensable gasses from the hoses. - Only connect the R-134a fluorescent dye injector to a manifold and gauge set or R-134a service center when fluorescent dye is to be injected. The R-134a fluorescent dye injector has a one way check valve that will prevent refrigerant system recovery and evacuation. - Refrigerant system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the engine off. 1. Connect an R-134a A/C refrigerant service center or a manifold and gauge set to the refrigerant system service port valves. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Testing and Inspection > Fluorescent Dye Leak Detection > Page 8932 2. Verify that the valves on the fluorescent dye injector are closed. 3. Fill the fluorescent dye injector reservoir with 7 ml (0.25 oz) of fluorescent dye. 4. Install the fluorescent dye injector between the low-pressure service gauge port valve and the R-134a refrigerant service center or manifold gauge set. 5. Open all valves and inject the fluorescent dye into the refrigerant system. 6. When fluorescent dye injection is complete, close all valves. 7. Recover the refrigerant from the R-134a fluorescent dye injector. 8. Remove the fluorescent dye injector from the low-pressure service gauge port valve and the R-134a A/C refrigerant service center or manifold gauge set. Fluorescent Dye Injection - Using a Dye Injector Loop Kit NOTE: - Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in refrigerant system leak diagnosis using a Rotunda-approved ultraviolet blacklight. It is not necessary to add additional dye to the refrigerant system before diagnosing leaks, even if a significant amount of refrigerant has been removed from the system. Replacement suction accumulators and receiver/driers are shipped with a fluorescent dye "wafer" included in the desiccant bag which will dissolve after approximately 30 minutes of continued A/C operation. It is not necessary to add dye after flushing or filtering the refrigerant system because a new suction accumulator or receiver/drier is installed as part of the flushing or filtering procedure. Additional refrigerant system dye should only be added if more than 50% of the refrigerant system lubricant capacity has been lost due to a fitting separation, hose rupture or other damage. - Before using the R-134a fluorescent dye injector for the first time, refer to the equipment manufacturers instructions on evacuation of non-condensable gasses from the hoses. - Refrigerant system pressure should be between 413-551 kPa (60-80 psi) at 24°C. 1. Verify that the valves on the deluxe injector loop kit are closed. 2. Fill the deluxe injector loop kit reservoir with 7 ml (0.25 oz) of fluorescent dye. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Testing and Inspection > Fluorescent Dye Leak Detection > Page 8933 3. Install the deluxe injector loop kit between the high-pressure and low-pressure service gauge port valves. 4. CAUTION: Make sure all tools and hoses are clear of the engine cooling fan and drive belt before starting the engine. Start the engine. 5. Open the high-pressure service valve. 6. Open the deluxe injector loop kit valves and inject the fluorescent dye into the refrigerant system. 7. Close the high-pressure service valve to allow the pressure inside the deluxe injector loop kit to equalize with the suction side of the refrigerant system. 8. NOTE: Close the valves on the deluxe injector loop kit while the A/C compressor is operating. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Testing and Inspection > Fluorescent Dye Leak Detection > Page 8934 Close the valves on the deluxe injector loop kit. 9. NOTE: Leave all valves on the special tool closed when not in use. Disconnect the high-pressure and low-pressure service valves and remove the deluxe injector loop kit from the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Testing and Inspection > Fluorescent Dye Leak Detection > Page 8935 Refrigerant: Testing and Inspection Electronic Leak Detection ELECTRONIC LEAK DETECTION H10PM Refrigerant Leak Detector With Battery Special Tool(s) CAUTION: Good ventilation is necessary in the area where electronic A/C leak testing is to be carried out. If the surrounding air is contaminated with refrigerant gas, the leak detector will indicate this gas all the time. Odors from other chemicals such as antifreeze, diesel fuel, disc brake cleaner or other cleaning solvents can cause the same problem. Using a fan to ventilate the area to be tested before proceeding with the leak detection procedure is helpful in removing small traces of contamination from the air, but the fan should be turned off during actual testing. 1. NOTE: The system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the engine off. Leak test the refrigerant system using the Refrigerant Leak Detector. Follow the instructions included with the leak detector for handling and operation techniques. 2. If a leak is found, recover the refrigerant. - Repair the system. - Test the system for normal operation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant Discharging and Recovery Procedure Refrigerant: Service and Repair Refrigerant Discharging and Recovery Procedure AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING Special Tool(s) Special Tool(s) Refrigerant System Recovery NOTE: - Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation and charging may be accomplished using a separate recovery station, vacuum pump, charging meter and manifold gauge set. - Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant Discharging and Recovery Procedure > Page 8938 1. Prior to recovering, you must verify the purity of the refrigerant. 2. Connect an R-134a refrigerant service center to the low- and high-pressure service gauge port valves following the operating instructions provided by the equipment manufacturer. 3. Recover the refrigerant from the system following the operating instructions provided by the equipment manufacturer. 4. Once the refrigerant service center has recovered the refrigerant, switch OFF the power supply. 5. Allow the system to set for about 2 minutes, and observe the system vacuum reading. If the vacuum is not lost, disconnect the recovery equipment. 6. If the system does lose vacuum, repeat Steps 3 through 5 until the vacuum level remains stable for 2 minutes. 7. Carry out the required repairs. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant Discharging and Recovery Procedure > Page 8939 Refrigerant: Service and Repair Evacuation and Charging AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING Special Tool(s) Special Tool(s) Refrigerant System Evacuation Using an R-134a Service Center NOTE: - Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation and charging may be accomplished using a separate recovery station, vacuum pump, charging meter and manifold gauge set. - Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant Discharging and Recovery Procedure > Page 8940 1. Connect an R-134a service center to the low- and high-pressure service gauge port valves following the operating instructions provided by the equipment manufacturer. 2. Evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) of vacuum and as close to 101.1 kPa (30 in-Hg) as possible. Continue to operate the vacuum pump for a minimum of 45 minutes. 3. Turn off the vacuum pump. Observe the low-pressure gauge for 5 minutes to make sure that the system vacuum is held. If vacuum is not held for 5 minutes, leak test the system, repair the leak and evacuate the system again. Refrigerant System Evacuation Using an R-134a Manifold Gauge Set NOTE: - Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation and charging may be accomplished using a separate recovery station, vacuum pump, charging meter and manifold gauge set. - Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. 1. Connect the R-134a manifold gauge set to the low-side and high-side service gauge port valves. 2. Connect the center (yellow) hose from the manifold gauge set to the suction port on the vacuum pump. 3. Open all valves on the R-134a manifold gauge set and both service gauge port valves. 4. Turn on the vacuum pump and evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) of vacuum and as close to 101.1 kPa (30 in-Hg) as possible. Continue to operate the vacuum pump for a minimum of 45 minutes. 5. Close the high-side and low-side valves on the manifold gauge set (not the service gauge port valves) and turn off the vacuum pump. 6. Observe the low-pressure gauge for 5 minutes to make sure that the system vacuum is held. If vacuum is not held for 5 minutes, leak test the system, repair the leak and evacuate the system again. Refrigerant System Charging Using an R-134a Service Center NOTE: - Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation and charging may be accomplished using a separate recovery station, vacuum pump, charging meter and manifold gauge set. - Leaks in refrigerant system service equipment, hoses or gauges can cause a leak that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. 1. Lubricate the refrigerant system with the correct amount of clean PAG oil. 2. Connect an R-134a A/C service center to the low-side and high-side service gauge port valves following the operating instructions provided by the equipment manufacturer. 3. Set the refrigerant charge amount, and charge the refrigerant system following the instructions provided by the equipment manufacturer. Refrigerant System Charging NOTE: - Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation and charging may be accomplished using a separate recovery station, vacuum pump, charging meter and manifold gauge set. - Leaks in refrigerant system service equipment, hoses or gauges can cause a leak that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. 1. Lubricate the refrigerant system with the correct amount of clean PAG oil. 2. Assemble the R-134a manifold gauge set, automatic refrigerant charging meter and R-134a supply tank following the automatic refrigerant charging meter operating instructions. 3. Charge the refrigerant system following the automatic refrigerant charging meter operating instructions. 4. If the refrigerant flow stops before the refrigerant charge is complete, start the engine, select A/C operation and allow the refrigerant charge to complete. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant Discharging and Recovery Procedure > Page 8941 Refrigerant: Service and Repair Refrigerant Identification Testing REFRIGERANT IDENTIFICATION TESTING Refrigerant Identifier With Air-Radicator Special Tool(s) Refrigerant Identification 1. NOTE: An A/C refrigerant analyzer must be used to identify gas samples taken directly from the refrigeration system or storage containers prior to recovering or charging the refrigerant system. Follow the instructions included with the refrigerant identifier to obtain the sample for testing. 2. The diagnostic tool will display one of the following: - If the purity level of R-134a is 98% or greater by weight, the green "PASS" light emitting diode (LED) will light. The weight concentrations of R-134a, R-12, R-22, hydrocarbons, and air will be displayed on the digital display. - If refrigerant R-134a does not meet the 98% purity level, the red "FAIL" LED will light and an alarm will sound alerting the user of potential hazards. The weight concentrations of R-134a, R-12, R-22, and hydrocarbons will be displayed on the digital display. - If hydrocarbon concentrations are 2% or greater by weight, the red "FAIL" LED will light, "Hydrocarbon High" will be displayed on the digital display, and an alarm will sound alerting the user of potential hazards. The weight concentrations of R-134a, R-12, R-22, and hydrocarbons will also be displayed on the digital display. 3. The percentage of air contained in the sample will be displayed if the R-134a content is 98% or greater. The diagnostic tool eliminates the effect of air when determining the refrigerant sample content because air is not considered a contaminant, although air can affect A/C system performance. When the diagnostic tool has determined that a refrigerant source is pure (R-134a is 98% or greater by weight) and air concentration levels are 2% or greater by weight, the diagnostic tool will prompt the user if an air purge is desired. 4. If contaminated refrigerant is detected, repeat the refrigerant identification test to verify that the refrigerant is indeed contaminated. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant Discharging and Recovery Procedure > Page 8942 Refrigerant: Service and Repair Contaminated Refrigerant Handling CONTAMINATED REFRIGERANT HANDLING CAUTION: If contaminated refrigerant is detected, DO NOT recover the refrigerant into R-134a recovery/recycling equipment. NOTE: A new suction accumulator or receiver/drier must be installed as directed by the air conditioning system flushing procedure. 1. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant only. - If this equipment is not available, contact an A/C service facility in your area with the correct equipment to carry out this service. 2. Determine and correct the cause of the customers initial concern. 3. Flush the air conditioning system. 4. Dispose of the contaminated refrigerant in accordance with all federal, state and local regulations. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications REFRIGERANT OIL TOTAL SYSTEM CAPACITY Without auxiliary climate control ............................................................................................................................................................ 266 ml (9.0 oz) With auxiliary climate control ...................................................................................... ......................................................................... 414 ml (14.0 oz) A/C COMPRESSOR Add the same amount drained plus the amount collected during refrigerant recovery. NOTE: Rotate the old A/C compressor shaft 8 to 10 full rotations (clockwise) while collecting the refrigerant oil in a clean measuring cup. Service A/C compressors are shipped without refrigerant oil. SUCTION ACCUMULATOR OR RECEIVER/DRIER Add the quantity of oil drained, plus the amount collected during refrigerant recovery and 60 ml (2.0 fl oz). NOTE: Drill one 12.7 mm (1/2 inch) hole in the old suction accumulator or receiver/drier cylinder and drain the oil into a clean measuring cup. EVAPORATOR CORE ........................................................................................................................ ................................................ 45 ml (1.5 fl oz.) NOTE: Added to the amount collected during refrigerant recovery. CONDENSER CORE .......................................................................................................................... ................................................. 60 ml (2.0 fl oz.) NOTE: Added to the amount collected during refrigerant recovery. EVAPORATOR CORE ORIFICE OR THERMOSTATIC EXPANSION VALVE The amount collected during refrigerant recovery. A/C PRESSURE RELIEF VALVE ...................................................................................................................................................... 60 ml (2.0 fl oz.) REFRIGERANT HOSE/LINE ............................................................................................................................................................. 60 ml (2.0 fl oz.) NOTE: If an excessive amount of refrigerant oil is lost due to a hose rupture/separation or other damage, the total system refrigerant oil capacity must be added. O-RING LEAK REPAIR ....................................................................................................................... .............................................. 60 ml (2.0 fl oz.) NOTE: The amount specified may be used for one or multiple O-ring leak repairs. Do not multiply the refrigerant oil amount by the number of O-ring leaks being repaired. SERVICE PORT LEAK REPAIR ....................................................................................................................................................... 60 ml (2.0 fl oz.) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 8947 Refrigerant Oil: Fluid Type Specifications REFRIGERANT OIL PAG Refrigerant Compressor Oil (R-134a Systems) Ford P/N .............................................................................................................................................. .................................................. F7AZ-19589-DA Motorcraft P/N ....................................................... ............................................................................................................................................. YN-12-C Ford Specification ................................................................................................................................ .................................................. WSH-M1C231-B Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 8948 Refrigerant Oil: Service and Repair REFRIGERANT OIL ADDING Special Tool(s) Special Tool(s) CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant, and a small amount is retained in each component. If certain components of the system are removed, some of the refrigerant oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part. Part 1 Part 2 1. Refer to the chart for refrigerant oil adding amounts and methods of installation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 8949 Refrigerant Oil Adding for New A/C Compressor Installation NOTE: Service A/C compressors are shipped without refrigerant oil. 1. Rotate the old A/C compressor shaft 8 to 10 full rotations (clockwise) while collecting the refrigerant oil in a clean measuring cup. - Add the same amount plus the amount collected during refrigerant recovery. Refrigerant Oil Adding for New Suction Accumulator or Receiver/Drier Installation 1. Drill one half-inch hole in the old suction accumulator or receiver/drier cylinder and drain the oil into a clean measuring cup. 2. Add the quantity of oil drained, plus the amount collected during refrigerant recovery and 60 ml (2 oz.). Oil Injection Using a Dye/Lubricant Injector NOTE: If fluorescent leak detection dye is also to be added during A/C charging, the dye may be added to the dye/lubricant injector along with the refrigerant oil. 1. Evacuate the refrigerant system. 2. Assemble the dye/lubricant injector using the correct adapters to match the amount of PAG oil to be injected. 3. Verify that all the valves on the dye/lubricant injector are closed. 4. Fill the dye/lubricant injector with the correct amount of clean PAG oil. 5. Install the dye/lubricant injector between the low-side service gauge port valve and the refrigerant service station or manifold gauge set. 6. Open all valves and charge the refrigerant system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 8954 C1078 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 8958 C130 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay Blower Motor Relay: Locations Front Blower Motor Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay > Page 8964 View 151-1 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay > Page 8965 Blower Motor Relay: Locations Rear Blower Motor Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay > Page 8966 View 151-21 (Right Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Front Blower Motor Relay C2216 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Front Blower Motor Relay > Page 8969 C4075 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay Blower Motor Relay: Testing and Inspection Front Blower Motor Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 8972 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 8973 Blower Motor Relay: Testing and Inspection Rear Blower Motor Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Front Blower Motor Relay > Page 8974 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 8978 View 151-1 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 8979 C1008 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 8980 Compressor Clutch Relay: Description and Operation AIR CONDITIONING (A/C) CLUTCH RELAY (A/CCR) NOTE: The PCM PIDs WAC and wide open throttle air conditioning cutoff fault (WACF) are used to monitor the A/CCR output. The A/CCR (may be referred to as the wide open throttle A/C cutoff [WAC] relay) is wired normally open. There is no direct electrical connection between the A/C switch or EATC module and the A/C clutch. The PCM receives a signal indicating that A/C is requested (for some applications, this message is sent through the communications network). When A/C is requested, the PCM will check other A/C related inputs that are available (such as ACPSW, ACCS). If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant temperature, engine RPM, throttle position), the PCM grounds the A/CCR output, closing the relay contacts and sending voltage to the A/CC. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 8981 Compressor Clutch Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 8982 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations View 151-12 (Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Page 8986 Control Module HVAC: Diagrams C228a Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Page 8987 C228b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations View 151-1 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 8992 C132 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 8993 Ambient Temperature Sensor Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 8994 Ambient Temperature Sensor / Switch HVAC: Service and Repair AMBIENT AIR TEMPERATURE SENSOR Removal and Installation Expedition 1. Remove the upper radiator sight shield. All vehicles 2. Detach and disconnect the ambient temperature sensor electrical connector. 3. Remove the ambient air temperature sensor. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service and Repair > Blower Motor Switch Blower Motor Switch: Service and Repair Blower Motor Switch BLOWER MOTOR SWITCH Removal and Installation 1. Remove the climate control assembly. 2. Pull and remove the blower motor switch knob. 3. Release the 3 clips and remove the blower motor switch. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Service and Repair > Blower Motor Switch > Page 8999 Blower Motor Switch: Service and Repair Blower Motor Speed Control BLOWER MOTOR SPEED CONTROL Removal and Installation 1. Remove the RH lower instrument panel insulator. 2. Disconnect the blower motor speed control electrical connector. 3. Remove the blower motor speed control screw. 4. Remove the blower motor speed control. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations View 151-12 (Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Diagrams > In-Vehicle Temperature Sensor C233 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Diagrams > In-Vehicle Temperature Sensor > Page 9005 C2247 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Diagrams > Page 9006 In-Vehicle Temperature Sensor Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > In-Vehicle Temperature Sensor Cabin Temperature Sensor / Switch: Service and Repair In-Vehicle Temperature Sensor IN-VEHICLE TEMPERATURE SENSOR Removal and Installation 1. Remove the instrument cluster finish panel. 2. Disconnect the aspirator hose and the in-vehicle temperature sensor electrical connector. 3. Remove the in-vehicle temperature sensor screws. 4. Remove the in-vehicle temperature sensor. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > In-Vehicle Temperature Sensor > Page 9009 Cabin Temperature Sensor / Switch: Service and Repair In-Vehicle Temperature and Humidity Sensor IN-VEHICLE TEMPERATURE AND HUMIDITY SENSOR Removal and Installation 1. Remove the in-vehicle temperature and humidity sensor trim cover. - Disconnect the electrical connector and aspirator tube. 2. Remove the 2 in-vehicle temperature and humidity sensor screws. 3. Remove the in-vehicle temperature and humidity sensor. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation Evaporator Temperature Sensor / Switch: Description and Operation AIR CONDITIONING EVAPORATOR TEMPERATURE (ACET) SENSOR A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance The ACET sensor measures the evaporator air discharge temperature. The ACET sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The PCM sources a low current 5 volts on the ACET circuit. With SIG RTN also connected to the ACET sensor, the varying resistance affects the voltage drop across the sensor terminals. As A/C evaporator air temperature changes, the varying resistance of the ACET sensor changes the voltage the PCM detects. The ACET sensor is used to more accurately control A/C clutch cycling, improve defrost/demist performance, and reduce A/C clutch cycling. NOTE: These values can vary 15 percent due to sensor and VREF variations. Voltage values were calculated for VREF equals 5.0 volts. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Page 9013 Evaporator Temperature Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) EVAPORATOR DISCHARGE AIR TEMPERATURE SENSOR Removal and Installation 1. Lower the glove compartment. 2. Remove the evaporator discharge air temperature sensor screw. 3. Disconnect the evaporator discharge air temperature sensor electrical connector. 4. Carefully pry the evaporator discharge air temperature sensor probe out of the heater core and evaporator core housing. 5. Remove the evaporator discharge air temperature sensor. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Humidity Sensor > Component Information > Diagrams C2247 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Humidity Sensor > Component Information > Diagrams > Page 9017 Humidity Sensor: Service and Repair IN-VEHICLE TEMPERATURE AND HUMIDITY SENSOR Removal and Installation 1. Remove the in-vehicle temperature and humidity sensor trim cover. - Disconnect the electrical connector and aspirator tube. 2. Remove the 2 in-vehicle temperature and humidity sensor screws. 3. Remove the in-vehicle temperature and humidity sensor. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 9022 C1078 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 9026 C130 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations View 151-10 (behind Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 9030 C286 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations Service Port HVAC: Locations Clutch Cycling Thermostatic Expansion Valve Type Refrigerant System (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page 9034 Clutch Cycling Thermostatic Expansion Valve Type Refrigerant System (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations View 151-10 (behind Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Page 9038 C286 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service and Repair Vacuum Harness HVAC: Service and Repair VACUUM HOSE REPAIR - MINI-TUBE Vacuum Pump Kit Special Tool(s) 1. Measure the length of the damaged area of the mini-tube vacuum hose. 2. Cut a piece of standard 1/8-inch inner diameter vacuum hose approximately 25 mm (1 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. WARNING: Read the warning information on the product label to prevent possible personal injury. Dip the mini-tube hose ends in commercially available paint thinner containing methyl ethyl ketone (MEK). This solvent will seal the mini-tube in the vacuum hose. 5. Insert the ends of the mini-tube vacuum hose approximately 9 mm (3/8 inch) into the ends of the standard 1/8-inch repair vacuum hose section. 6. Shake the repair joint after assembly to make sure the solvent is dispersed and the vacuum line is not plugged. 7. Test the system for a vacuum leak in the repair area. - Use the Vacuum Pump or equivalent. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Service and Repair Vacuum Reservoir HVAC: Service and Repair VACUUM RESERVOIR Removal and Installation 1. Remove the battery and battery tray. 2. Disconnect the vacuum reservoir vacuum connector. 3. Remove the vacuum reservoir. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Solenoid Valve HVAC > Component Information > Locations View 151-12 (Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Solenoid Valve HVAC > Component Information > Locations > Page 9048 C2093 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Solenoid Valve HVAC > Component Information > Locations > Page 9049 ATC Solenoid And Manifold Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Solenoid Valve HVAC > Component Information > Locations > Page 9050 Vacuum Solenoid Valve HVAC: Service and Repair AUTOMATIC TEMPERATURE CONTROL SOLENOID AND MANIFOLD Removal and Installation Navigator 1. Remove the floor console trim panel. Expedition 2. Remove the bolts and the instrument panel brace. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Solenoid Valve HVAC > Component Information > Locations > Page 9051 All vehicles 3. Disconnect the automatic temperature control (ATC) solenoid and manifold vacuum connector. 4. Disconnect the ATC solenoid and manifold electrical connector. 5. Remove the ATC solenoid and manifold screw. 6. Remove the ATC solenoid and manifold. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Inspection and Repair After A Supplemental Restraint System (SRS) Deployment Repairs and Inspections Required After a Collision: Service and Repair Inspection and Repair After A Supplemental Restraint System (SRS) Deployment Inspection and Repair After a Supplemental Restraint System (SRS) Deployment WARNING: Remove restraint system diagnostic tools from the vehicle prior to road testing. If tools are not removed, the supplemental restraint system (SRS) device may not deploy in a crash. Failure to follow this instruction may result in serious personal injury or death in a crash and possibly violate vehicle safety standards. NOTE: After diagnosing or repairing a supplemental restraint system (SRS), the restraint system diagnostic tools (if required) must be removed before operating the vehicle over the road. NOTE: Deployable devices (such as air bag modules, pretensioners) may deploy alone or in various combinations depending on the impact event. NOTE: Always refer to the appropriate workshop manual procedures prior to carrying out vehicle repairs affecting the SRS and safety belt system. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. NOTE: Refer to the correct removal and installation procedure for all SRS components being installed. When any deployable device or combination of devices are deployed and/or the restraints control module (RCM) has the DTC B1231 (Event Threshold Exceeded) in memory, the repair of the vehicle's SRS is to include the removal of all deployed devices and the installation of new deployable devices, the removal and installation of new impact sensors, and the removal and installation of a new RCM. DTCs must cleared from all required modules after repairs are carried out. Vehicles with occupant classification sensor (OCS) system 2. NOTE: After installation of new occupant classification sensor (OCS) system components carry out the OCS System Reset procedure as instructed in the workshop manual. Refer to the appropriate workshop manual for OCS system removal and installation procedure. When a vehicle has been involved in a collision and the occupant classification system module (OCSM) has DTC B1231 stored in memory, the repair of the OCS system is to include the following procedures for the specified system: - For rail type OCS system, inspect the passenger side floorpan for damage and repair as necessary. Install new OCS system rails. - For weight sensor bolt type OCS system, inspect the passenger side floorpan for damage and repair as necessary. Install a new seat track with OCS system weight sensor bolts. DTC must be cleared from the OCSM before carrying out Occupant Classification Sensor (OCS) System Reset. Do not install a new OCSM unless DTC B1231 cannot be cleared. - NOTE: Most bladder type OCSM do not store a DTC B1231 in memory after deployment. The DTC B1231 is stored only by the RCM. For bladder type OCS system, inspect for damage and repair as necessary. If installation of an OCS system component is required, an OCS system service kit must be installed. All vehicles 3. When any damage to the impact sensor mounting points or mounting hardware has occurred, repair or install new mounting points and mounting hardware as needed. 4. When the driver air bag module has deployed, a new clockspring must be installed. 5. New driver and/or front passenger safety belt systems (including retractors, buckles and height adjusters) must be installed if the vehicle is involved in a collision that results in deployment of the driver and/or front passenger safety belt pretensioners. For additional information, refer to Safety Belt System. 6. Inspect the entire vehicle for damage, including the following components: Steering column (deployable column if equipped) Instrument panel knee bolsters and mounting points Instrument panel braces and brackets Instrument panel and mounting points Seats and seat mounting points Safety belts, safety belt buckles and safety belt retractors. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Inspection and Repair After A Supplemental Restraint System (SRS) Deployment > Page 9057 SRS wiring, wiring harnesses and connectors 7. After carrying out the review and inspection of the entire vehicle for damage, repair or install new components as needed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Inspection and Repair After A Supplemental Restraint System (SRS) Deployment > Page 9058 Repairs and Inspections Required After a Collision: Service and Repair Safety Belt Procedure After A Collision SAFETY BELT PROCEDURE AFTER A COLLISION WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing portion of this section, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 1. Before installing a new safety belt assembly, the safety belt attaching areas must be inspected for damage and distortion. If the attaching points are damaged and distorted, the sheet metal must be worked back to its original shape and structural integrity. 2. Install the new safety belt(s). Carry out all applicable Functional Tests for the component(s). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Depowering and Repowering SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING Depowering Procedure WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the electrical connector on a safety canopy module. Doing so can result in safety canopy deployment. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the RH side of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse 19 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located at the bottom of the hood latch support bracket. The first row side impact sensors (if equipped) are located in the first row doors, behind the door trim panel. The second row side impact sensors (if equipped) are located at or near the base of the C-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install the RCM fuse 19 (10A) to the CJB and close the cover. 4. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9064 Connect the battery ground cable. 5. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a diagnostic tool. Deactivation and Reactivation SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION Special Tool(s) Special Tool(s) Deactivation WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the connectors on the safety canopy module. Doing so can result in safety canopy module deployment. - To reduce the risk of personal injury, do not use any memory saver devices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9065 NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the RH side of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse 19 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located at the bottom of the hood latch support bracket. The first row side impact sensors (if equipped) are located in the first row doors, behind the door trim panel. The second row side impact sensors (if equipped) are located at or near the base of the C-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 7. Remove the 2 steering wheel back cover plugs (1 shown). 8. Remove the 2 driver air bag module bolts (1 shown). Expedition Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9066 9. Remove the driver air bag module. 1 Release the 2 retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector before disconnecting. 2 Release the 2 retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector before disconnecting. 3 Disconnect the horn switch electrical connector. 4 Remove the driver air bag module. Navigator 10. Disconnect the driver air bag module. - Release the 2 tabs on each driver air bag module electrical connector and disconnect them. Label each driver air bag module electrical connector before disconnecting. 11. Release the tab and disconnect the driver air bag module accessories electrical connector at the top of the clockspring and remove the driver air bag module. All vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9067 12. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of the steering column. 13. While pushing in on the 2 glove compartment door tabs, position the glove compartment downward. 14. NOTE: Expedition shown, Navigator similar. Through the glove compartment opening, release the tab and disconnect the passenger air bag module electrical connector. 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Vehicles with safety canopies Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9068 16. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or if it does not remain closed, install a new shoulder safety belt guide cover. Remove the second row passenger side safety belt guide. 1 Release the retaining tab at each side and open the safety belt guide cover. 2 Remove the nut. 3 Remove the second row passenger side safety belt guide. 17. Remove the passenger side C-pillar trim panel. 1 Separate the weather-stripping along the passenger side C-pillar trim panel. 2 Remove the bolt cover and bolt. 3 Pull out to release the retainers and remove the passenger side C-pillar trim panel. 18. Disconnect the passenger side safety canopy electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9069 19. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy electrical connector. 20. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or if it does not remain closed, install a new shoulder safety belt guide cover. Remove the second row driver side safety belt guide. 1 Release the retaining tab at each side and open the safety belt guide cover. 2 Remove the nut. 3 Remove the second row driver side safety belt guide. 21. Remove the driver side C-pillar trim panel. 1 Separate the weather-stripping along the driver side C-pillar trim panel. 2 Remove the bolt cover and bolt. 3 Pull out to release the retainers and remove the driver side C-pillar trim panel. 22. Disconnect the driver side safety canopy electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9070 23. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy electrical connector. All vehicles 24. Install the RCM fuse 19 (10A) to the CJB. 25. Connect the battery ground cable. Reactivation All vehicles 1. Remove the RCM fuse 19 (10A) from the CJB. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles with safety canopies 3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy electrical connector. 4. Connect the driver side safety canopy electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9071 5. WARNING: Anytime the safety canopy module has deployed, the headliner, and all A, B, and C pillar upper trim panels and attaching hardware must be replaced along with any other damaged components and hardware. Failure to do so may result in personal injury in the event of a safety canopy module deployment. Install the driver side C-pillar trim panel. 1 Position the driver side C-pillar trim panel and push in, engaging the retainers. 2 Install the bolt and bolt cover. Tighten to 11 Nm (8 lb-ft). 3 Install the weather-stripping along the driver side C-pillar trim panel. 6. NOTE: - Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or if it does not remain closed, install a new shoulder safety belt guide cover. - Make sure the safety belt is not twisted prior to installation. Install the second row driver side safety belt guide. 1 Position the second row driver side safety belt guide. 2 Install the nut. Tighten to 40 Nm (30 lb-ft). 3 Close the safety belt guide cover. Verify the safety belt retractor operates without excessive effort or binding. 7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9072 8. Connect the passenger side safety canopy electrical connector. 9. WARNING: Anytime the safety canopy module has deployed, the headliner, and all A, B, and C pillar upper trim panels and attaching hardware must be replaced along with any other damaged components and hardware. Failure to do so may result in personal injury in the event of a safety canopy module deployment. Install the passenger C-pillar trim panel. 1 Position the passenger side C-pillar trim panel and push in, engaging the retainers. 2 Install the bolt and bolt cover. Tighten to 11 Nm (8 lb-ft). 3 Install the weather-stripping along the passenger side C-pillar trim panel. 10. NOTE: - Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or if it does not remain closed, install a new shoulder safety belt guide cover. - Make sure the safety belt is not twisted prior to installation. Install the second row passenger side safety belt guide. 1 Position the second row passenger side safety belt guide. 2 Install the nut. Tighten to 40 Nm (30 lb-ft). 3 Close the safety belt guide cover. Verify the safety belt retractor operates without excessive effort or binding. All vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9073 11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. 12. NOTE: Expedition shown, Navigator similar. Connect the passenger air bag module electrical connector. 13. Close the glove compartment. 14. Remove the restraint system diagnostic tools from the clockspring electrical connector at the top of the steering column. Navigator 15. Connect the driver air bag module accessories electrical connector to the connector end at the top of the clockspring. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9074 16. CAUTION: The clockspring electrical connectors are unique and cannot be reversed when connected to the driver air bag module. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Connect the driver air bag module electrical connectors as noted during removal. Position the driver air bag module to the steering wheel. Expedition 17. Position the driver air bag module to the steering wheel. 1 Connect the horn switch electrical connector. 2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when connected to the driver air bag module. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Connect the driver air bag module electrical connectors as noted during removal. 3 Position the driver air bag module to the steering wheel. All vehicles 18. Install the 2 driver air bag module bolts (1 shown). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9075 19. Install the 2 steering wheel back cover plugs (1 shown). 20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse 19 (10A) to the CJB and close the cover. 23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a diagnostic tool. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9076 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure PROVE OUT PROCEDURE Turn the ignition switch from the OFF to the ON position and visually monitor the air bag indicator with all SRS components connected or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an SRS fault is present, the air bag indicator will: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations View 151-10 (behind Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Passenger Air Bag Module C256 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Passenger Air Bag Module > Page 9082 C9006 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Passenger Air Bag Module > Page 9083 C9007 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Page 9084 Air Bag: Description and Operation Driver Air Bag Module The driver air bag module: is installed new as an assembly. - is mounted in the center of the steering wheel. - cannot be interchanged between Expedition and Navigator vehicles. Passenger air Bag Module The passenger air bag module: is installed new as an assembly. - is mounted in the passenger side of the instrument panel. - cannot be interchanged between Expedition and Navigator vehicles. Safety Canopy Module Some vehicles can be equipped with optional safety canopies for protection during side impacts or rollovers. Vehicles equipped with safety canopies require a specific headliner. When installing a new headliner on a vehicle equipped with safety canopies, make sure a headliner for safety canopies is being used. The word "AIRBAG" will appear on the headliner where it meets each B-pillar trim panel. The safety canopy module: is installed as an assembly. - is mounted above the headliner. - attaches from the A-pillar frame to the C-pillar frame. - is standard equipment on the Navigator and optional on the Expedition. - cannot be interchanged from side to side. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module Air Bag: Service and Repair Driver Air Bag Module DRIVER AIR BAG MODULE Expedition Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 9087 Navigator Removal WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 9088 All vehicles 1. Depower the system. 2. Remove the 2 steering wheel back cover plugs. 3. Remove the 2 driver air bag module bolts. Expedition 4. Disconnect the 2 driver air bag module electrical connectors. 5. Disconnect the horn switch electrical connector and remove the driver air bag module. Navigator 6. Disconnect the 2 driver air bag module electrical connectors. 7. Disconnect the steering wheel controls electrical connector at the top of the clockspring and remove the driver air bag module. Installation Navigator 1. Connect the steering wheel controls electrical connector at the top of the clockspring and remove the driver air bag module. 2. CAUTION: The clockspring electrical connectors are unique and cannot be reversed when connected to the driver air bag module. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Connect the 2 driver air bag module electrical connectors and position the driver air bag module to the steering wheel. Expedition 3. Connect the horn switch electrical connector. 4. CAUTION: The clockspring electrical connectors are unique and cannot be reversed when connected to the driver air bag module. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Connect the 2 driver air bag module electrical connectors and position the driver air bag module to the steering wheel. All vehicles 5. NOTE: - Inspect the driver air bag module back surface and steering wheel sides for any loose components or objects. Cycle the plate spring and make sure the horn mechanism functions correctly. - Make sure to tighten the bolts in 2 stages to prevent horn effort concerns. While holding the driver air bag module in place, keep it still at the center of the steering wheel and install the 2 bolts. Stage 1: Tighten the outboard bolt (nearest the driver door) then the inboard bolt to 5 Nm (44 lb-in). - Stage 2: Tighten the outboard bolt and then the inboard bolt to 9 Nm (80 lb-in). 6. CAUTION: If the opening between the driver air bag module trim cover and steering wheel is not uniform, the horn mechanism may not function correctly. Inspect the opening between the driver air bag module trim cover and the steering wheel. If the opening is not uniform, remove the 2 bolts and carry out the previous step once again. 7. Install the 2 steering wheel back cover plugs. 8. Repower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 9089 Air Bag: Service and Repair Passenger Air Bag Module PASSENGER AIR BAG MODULE Expedition Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 9090 Navigator Removal and Installation WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and deployment door pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the deployment door face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Air bag modules with discolored or damaged deployment doors must be replaced, not repainted. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 9091 - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. All vehicles 1. Depower the system. 2. Open and lower glove compartment door. 3. Disconnect the passenger air bag module electrical connector. Expedition 4. Remove the 3 air bag module bolts. - To install, tighten to 12 Nm (9 lb-ft). Navigator 5. Remove the 3 air bag module bolts. - To install, tighten to 9 Nm (80 lb-in). All vehicles 6. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove box opening, push out on the passenger air bag module and remove the passenger air bag module from the instrument panel. 7. To install, reverse the removal procedure. 8. Repower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 9092 Air Bag: Service and Repair Safety Canopy Module SAFETY CANOPY MODULE Removal Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 9093 WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - To reduce the risk of personal injury from an accidental deployment, always carry or place a live safety canopy module with the safety canopy and tear seam pointed away from your body. Failure to do so can result in personal injury in the event of a safety canopy module deployment. - After deployment, the surface of the safety canopy 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 connector on the safety canopy module. Doing so can result in safety canopy deployment which can result in personal injury. - Anytime the safety canopy has deployed, the headliner, and all A, B, and C pillar upper trim panels and attaching hardware must be replaced along with any other damaged components and hardware. Failure to do so can result in personal injury in the event of a safety canopy deployment. - Vehicles equipped with safety canopy modules require a specific headliner. When installing a new headliner on a vehicle equipped with safety canopy modules, make sure a headliner for safety canopy modules is being used. The word "AIRBAG" will appear on the headliner where it meets each B-pillar trim panel. Failure to do so can result in personal injury in the event of a safety canopy module deployment. - Before installing the safety canopy module, inspect the roofline for any damage. If necessary, the sheet metal must be reworked to its original condition and structural integrity. All damaged fasteners must be replaced and any foreign objects removed. Failure to do so may result in personal injury in the event of a safety canopy deployment. - Inspect the safety canopy before installation. If the safety canopy is damaged or the cover has separated or safety canopy material has been exposed, a new safety canopy module must be installed. Do not attempt to repair the safety canopy module. Failure to follow these instructions can result in personal injury in the event of a safety canopy module deployment. - To reduce the risk of injury, do not obstruct or place objects in the deployment path of the safety canopy module. Failure to follow these instructions can result in personal injury in the event of a safety canopy module deployment. - Never put any type of fastener or tie strap around any part of the safety canopy module or interior trim panel. This will prevent the safety canopy module from deploying correctly. Failure to do so can result in personal injury in the event of a safety canopy module deployment. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. - Passenger side safety canopy module shown, driver side similar. All vehicles 1. Depower the system. 2. Remove the headliner. Vehicles with a moonroof 3. Separate the moonroof drain tube and position to the side. All vehicles 4. CAUTION: Inspect the rivet nut and A-pillar sheet metal for damage. Install a new rivet nut if necessary. Remove the front tether cord bolt and bracket from the A-pillar. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 9094 5. NOTE: If not installing a new safety canopy module, the pin-type retainer can remain installed. Remove the front tether cord and pin-type retainer from the A-pillar. 6. Remove the safety canopy module bolt at the roofline near the A-pillar. 7. Remove the 2 bolts and slide up and rotate out the rear tether bracket assembly from the C-pillar. 8. Disconnect the safety canopy module electrical connector. 9. Remove the safety canopy wire harness and electrical connector pin-type retainers at the C-pillar. 10. Remove the safety canopy module rear ramp bolt. 11. Remove the 3 safety canopy module canister bolts. 12. Remove the 2 safety canopy module front ramp bolts. 13. Slide the front of the safety canopy up and rotate the hook out of the roofline sheet metal and remove the safety canopy. Installation All vehicles 1. WARNING: - Before installing the safety canopy module, inspect the roofline for any damage. If necessary, the sheet metal must be reworked to its original condition and structural integrity. All damaged fasteners must be replaced and any foreign objects removed. Failure to do so may result in personal injury in the event of a safety canopy module deployment. - Before installing the safety canopy module, if the module is damaged or the cover has separated or the safety canopy material has been exposed, install a new safety canopy module. Do not attempt to repair the safety canopy. Failure to follow these instructions could result in personal injury in the event of a safety canopy deployment. - Never put any type of fastener or tie strap around any part of the safety canopy module or interior trim panel. This will prevent the safety canopy module from deploying correctly. Failure to do so can result in personal injury in the event of a safety canopy module deployment. With the safety canopy module positioned in the vehicle as shown, angle the rear of the safety canopy module to the sheet metal, so that the deployment canister can be inserted into the sheet metal opening. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 9095 2. Position the safety canopy and engage the front hook to the roofline sheet metal. 3. Install the safety canopy module bolt at the roofline near the A-pillar. - Tighten to 8 Nm (71 ft-in). 4. Install the 2 safety canopy module front ramp bolts. - Tighten to 7 Nm (62 lb-in). 5. Install the safety canopy module rear ramp bolt. - Tighten to 7 Nm (62 lb-in). 6. Install the 3 safety canopy module canister bolts. - Tighten to 7 Nm (62 lb-in). 7. Route and install the safety canopy wire harness and electrical connector pin-type retainers at the C-pillar. 8. Connect the safety canopy electrical connector. 9. Rotate and slide down the rear tether bracket assembly hook engaging it to the C-pillar sheet metal, then install the 2 bolts. - Tighten to 7 Nm (62 lb-in). 10. Install the front tether cord bolt and bracket to the A-pillar. - Tighten to 7 Nm (62 lb-in). 11. Make sure the tether is securely engaged into the pin-type retainer and install the pin-type retainer to the A-pillar. - If a new safety canopy module was not installed, route the tether and securely engage it into the pin-type retainer at the A-pillar. Vehicles with a moonroof 12. Route and connect the moonroof drain tube. All vehicles 13. Install the headliner. 14. Repower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations View 151-15 (LH A-Pillar) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 9099 Air Bag And Safety Belt Pretensioner Supplemental Restraint System (SRS) Deployable Components (Part 1) Air Bag And Safety Belt Pretensioner Supplemental Restraint System (SRS) Deployable Components (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 9100 Air Bag And Safety Belt Pretensioner Supplemental Restraint System (SRS) Sensor Components (Part 1) Air Bag And Safety Belt Pretensioner Supplemental Restraint System (SRS) Sensor Components (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 9101 Air Bag Control Module: Diagrams C310a Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 9102 C310b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 9103 Air Bag Control Module: Description and Operation RESTRAINTS CONTROL MODULE (RCM) WARNING: - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the RCM must be replaced whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. NOTE: When installing a new restraints control module (RCM), always make sure the correct RCM is being installed. If an incorrect RCM is installed, erroneous DTCs will result. The restraints control module (RCM) carries out the following functions: - deploys the air bag(s) in the event of a deployable crash. - activates the safety belt buckle pretensioners to remove slack from the safety belt. - monitors the 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 instrument cluster module to activate a chime if the air bag indicator is not available and another SRS fault exists. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the ON position, the RCM will 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 prove out by lighting for 6 seconds and then off for 2 seconds. After the prove out, the air bag indicator will then flash the 2-digit LFC. If an SRS fault exists, the air bag indicator will flash the LFC 5 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 DLC, to the diagnostic tool. If the air bag indicator does not function, and the system detects a fault condition, the RCM will signal the instrument cluster module to activate an audible chime. The chime is a series of 5 sets of 5 tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If 2 or more faults occur at the same time, the fault having the highest priority will be displayed. After that 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 front air bags and safety belt pretensioners in the event that the ignition circuit is lost or damaged during impact. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 9104 Air Bag Control Module: Service and Repair RESTRAINTS CONTROL MODULE (RCM) Vehicles With A Center Console Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 9105 Vehicles With 60/40 Front Bench Seat 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. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - The restraints control module (RCM) orientation is critical for proper air bag supplemental restraint system (SRS) operation. If a vehicle equipped with an SRS system has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the RCM must be replaced whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. - To reduce the risk of personal injury, do not use any memory saver devices. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - When installing a new restraints control module (RCM), always make sure the correct RCM is being installed. If an incorrect RCM is installed, erroneous DTCs will result. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. All vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 9106 1. Depower the system. Vehicles with a center console 2. Remove the center console. Vehicles with 60/40 front bench seat 3. Remove the 60 percent portion of the front bench seat. 4. Remove the 3 nuts and the restraints control module (RCM) top bracket. 5. WARNING: Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. Remove the 3 nuts and separate the RCM from the bracket. All vehicles 6. Disconnect the small restraints control module (RCM) electrical connector. 1 Push down to release the retaining tab. 2 While releasing the retaining tab, pull out and disconnect the small RCM electrical connector. 7. Disconnect the large RCM electrical connector. 1 Pinch the thumb tab and pivot the connector position assurance lever away from the RCM, disengaging the lever. 2 Pull out and disconnect the large RCM electrical connector. Vehicles with 60/40 front bench seat 8. Remove the RCM. Vehicles with a center console 9. Remove the 4 RCM bracket bolts and RCM with the bracket. Installation Vehicles with a center console 1. WARNING: The tightening torque of the air bag restraints control module (RCM) bracket retaining bolts is critical for correct system operation. Position the RCM with bracket and install the 4 bolts. Tighten to 12 Nm (9 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 9107 All vehicles 2. Make sure the connector position assurance lever is in the full release position before attempting to connect the connector. 3. CAUTION: Putting the large RCM electrical connector into the RCM on an angle can cause bad electrical connections and damage components. Position the large RCM electrical connector into the RCM. - CAUTION: Do not push the connector on to where the lever pivots and seats itself. Light pressure is needed to get the connector into position on the RCM before using the lever to fully seat the connector. With the large RCM electrical connector uniformly aligned to the RCM, lightly push in until a subtle audible click is heard and slight resistance is felt. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 9108 4. Connect the RCM electrical connector. - Pivot the connector position assurance lever toward the RCM, drawing the connector in to the RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place. 5. Connect the small RCM electrical connector. Vehicles with 60/40 front bench seat 6. WARNING: The tightening torque of the air bag restraints control module (RCM) to bracket retaining nuts is critical for correct system operation. Position the RCM to the bracket and install the 3 nuts. Tighten to 12 Nm (9 lb-ft). 7. Position the RCM top bracket and install the nuts. - Tighten to 12 Nm (9 lb-ft). Vehicles with a center console 8. Install the center console. Vehicles with 60/40 front bench seat 9. Install the 60 percent portion of the front bench seat. All vehicles 10. Repower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams Clockspring Assembly / Spiral Cable: Diagrams C218a C218b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 9112 Clockspring Assembly / Spiral Cable: Description and Operation CLOCKSPRING The clockspring: - is mounted on the steering column, behind the steering wheel. - allows for continuous electrical connections between the driver air bag module and the restraints control module (RCM) when the steering wheel is turned. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 9113 Clockspring Assembly / Spiral Cable: Service and Repair CLOCKSPRING Removal WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 9114 1. Depower the system. 2. CAUTION: Make sure the road wheels are in the straight-ahead position. Remove the steering wheel. 3. Apply 2 strips of masking tape across the clockspring to prevent accidental rotation when the clockspring is removed. 4. If equipped, release the tabs and slide the gear selector cover away from the steering column shrouds. 5. From under the steering column, remove the 2 screws and the lower steering column shroud. 6. From under the steering column remove the screw and then remove the upper steering column shroud. 7. Remove the multi-function switch screw. 8. While releasing the retaining tab on the top, slide the multi-function switch up and out of the way. 9. Remove the screws and slide the clockspring off the steering column shaft. 10. Disconnect the clockspring electrical connectors and remove the clockspring. 11. Inspect the clockspring bracket for damage and remove as necessary. Installation Vehicles receiving a new clockspring bracket 1. Install the clockspring bracket and screws. - Tighten to 6 Nm (53 lb-in). Vehicles receiving a new clockspring 2. NOTE: A new clockspring is supplied in a centralized position and held there with a key. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 9115 Remove the key from the clockspring, holding the rotor in its centralized position. Do not allow the clockspring rotor to turn. Vehicles needing clockspring recentering 3. WARNING: Incorrect centralization may result in premature component failure. If in doubt when centralizing the clockspring, repeat the centralizing procedure. Failure to follow this instruction may result in personal injury. CAUTION: Make sure the road wheels are in the straight-ahead position. NOTE: If a clockspring has rotated out of center, follow through with this step. Centralize the clockspring. 1 Hold the clockspring outer housing stationary. 2 CAUTION: Overturning will destroy the clockspring. The internal ribbon wire acts as the stop and can be broken from its internal connection. While turning the rotor counterclockwise, carefully feel for the ribbon wire to run out of length. Stop turning when a slight resistance is felt. 3 Turn the clockspring clockwise approximately 2.75 turns. This is the center point of the clockspring. Do not allow the rotor to turn from this position. All vehicles 4. Connect the clockspring electrical connectors. 5. NOTE: Slight turning of the clockspring rotor is allowable for alignment purposes to the steering column. With the flats of the clockspring aligned to the flats of the steering column, slide the clockspring onto the steering column and install the screws. Vehicle repairs using the same clockspring 6. Remove the tape applied during clockspring removal. All vehicles 7. Align the multi-function switch and slide it down into position and make sure the retaining tab is engaged. 8. Install the multi-function switch screw. 9. Position the upper steering column shroud, and from under the steering column, install the screw. 10. Position the lower steering column shroud and install the 2 screws. 11. If equipped, reposition the gear selector cover to the steering column shrouds and engage the tabs. 12. CAUTION: If the vehicle is left unattended by the technician between centralizing the clockspring and installing the steering wheel, the centralizing procedure must be repeated. Install the steering wheel. 13. Install the driver air bag module. 14. Repower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor View 151-1 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 9120 View 151-19 (Left Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 9121 View 151-21 (Right Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 9122 View 151-28 (Driver Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 9123 View 151-29 (Passenger Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Forward Crash Sensor C177 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Forward Crash Sensor > Page 9126 C539 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Forward Crash Sensor > Page 9127 C631 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Forward Crash Sensor > Page 9128 C9004 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Forward Crash Sensor > Page 9129 C9005 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Page 9130 Impact Sensor: Description and Operation SENSORS WARNING: - The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the RCM must be replaced whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. - Vehicle sensor orientation is critical for correct 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 correctly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. For these vehicles, the SRS uses up to 8 sensors. Within the RCM there can be up to 3 safing sensors which are not separately serviced. The RCM will always have at least 1 safing sensor for front impact. Two more safing sensors are used if the vehicle is equipped with safety canopy modules. The RCM is mounted to the center tunnel beneath the console or bench seat. All vehicles will have a front impact severity sensor that is located in the front-center of the vehicle, mounted near the bottom of the hood latch support bracket. If the vehicle is equipped with safety canopy modules, there are 4 additional side impact sensors external to the RCM. One front row side impact sensor is located behind each of the front door interior trim panels. One second row side impact sensor is located at the base of each C-pillar. Mounting orientation is critical for correct operation of all impact and rollover sensors. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor Impact Sensor: Service and Repair Front Impact Severity Sensor FRONT IMPACT SEVERITY SENSOR Removal and Installation WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - Front bumper removed for clarity. 1. Depower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 9133 2. NOTE: The front impact severity sensor is mounted on the bottom of the hood latch support bracket. Remove the pin-type retainers and lower the front lower splash shield to access the front impact severity sensor. 3. WARNING: The tightening torque of the air bag front impact severity sensor retaining nut is critical for correct system operation. CAUTION: If the hood latch support bracket or weld stud are damaged in any way that would affect the way the front impact severity sensor mounts to its original manufactured position, a new hood latch support bracket must be installed. NOTE: Note the position of the front impact severity sensor locator tabs to the hood latch support bracket alignment holes for installation. - Make sure the hood latch support bracket and front impact severity sensor mating surfaces are clean and debris free. Remove the front impact severity sensor nut. To install, tighten to 12 Nm (9 lb-ft) 4. Disconnect the electrical connector and remove the front impact severity sensor. 5. To install, reverse the removal procedure. 6. Repower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 9134 Impact Sensor: Service and Repair Side Impact Sensor - C-Pillar SIDE IMPACT SENSOR - C-PILLAR 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. - Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and correctly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To reduce the risk of personal injury, do not use any memory saver devices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 9135 NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. - Driver side shown, passenger side similar. 1. Depower the system. 2. Lift to release and remove the rear door scuff plate. 3. Remove the safety belt retractor anchor bolt. 4. Pull out at the front of the rear quarter trim panel, releasing the retaining clips, allowing access to the side impact sensor. 5. Remove the side impact sensor bolt. 6. Disconnect the side impact sensor electrical connector and remove the sensor and bracket. Installation 1. Make sure the second row side impact sensor tabs are aligned to the bracket. 2. Position the side impact sensor and bracket locator pin to the opening in the quarter panel sheet metal and install the bolt. - To install, tighten to 12 Nm (9 lb-ft). 3. Connect the side impact sensor electrical connector. 4. Align the rear quarter trim panel and push in, seating the retaining clips. 5. NOTE: Make sure the safety belt webbing is not twisted prior to installation. Install the safety belt retractor anchor bolt. To install, tighten to 40 Nm (30 lb-ft). - Verify the safety belt retractor operates without excessive effort or binding. 6. Install the rear door scuff plate. 7. Repower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 9136 Impact Sensor: Service and Repair Side Impact Sensor - Front Door SIDE IMPACT SENSOR - FRONT DOOR Removal and Installation WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Vehicle sensor orientation is critical for 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 reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - Driver side shown, passenger side similar. 1. Depower the system. 2. Remove the front interior door trim panel on the side with the affected side impact sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 9137 3. Separate the weathershield enough to access the side impact sensor. 4. Disconnect the side impact sensor electrical connector. 5. WARNING: The tightening torque of the side impact sensor retaining bolt is critical for correct system operation. CAUTION: The ground wire must be placed between the bolt head and the sensor. Never position the ground wire between the J-clip retaining nut and the sensor. - Always replace the J-clip retaining nut whenever installing a side impact sensor. NOTE: Make sure the side impact sensor mating surfaces are clean and free of foreign material. - Note the position of the side impact sensor locating tabs for installation. Remove the bolt and the side impact sensor. To install, tighten to 12 Nm (9 lb-ft). 6. To install, reverse the removal procedure. 7. Repower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations View 151-15 (LH A-Pillar) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 9142 Air Bag And Safety Belt Pretensioner Supplemental Restraint System (SRS) Deployable Components (Part 1) Air Bag And Safety Belt Pretensioner Supplemental Restraint System (SRS) Deployable Components (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 9143 Air Bag And Safety Belt Pretensioner Supplemental Restraint System (SRS) Sensor Components (Part 1) Air Bag And Safety Belt Pretensioner Supplemental Restraint System (SRS) Sensor Components (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 9144 Air Bag Control Module: Diagrams C310a Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 9145 C310b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 9146 Air Bag Control Module: Description and Operation RESTRAINTS CONTROL MODULE (RCM) WARNING: - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the RCM must be replaced whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. NOTE: When installing a new restraints control module (RCM), always make sure the correct RCM is being installed. If an incorrect RCM is installed, erroneous DTCs will result. The restraints control module (RCM) carries out the following functions: - deploys the air bag(s) in the event of a deployable crash. - activates the safety belt buckle pretensioners to remove slack from the safety belt. - monitors the 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 instrument cluster module to activate a chime if the air bag indicator is not available and another SRS fault exists. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the ON position, the RCM will 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 prove out by lighting for 6 seconds and then off for 2 seconds. After the prove out, the air bag indicator will then flash the 2-digit LFC. If an SRS fault exists, the air bag indicator will flash the LFC 5 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 DLC, to the diagnostic tool. If the air bag indicator does not function, and the system detects a fault condition, the RCM will signal the instrument cluster module to activate an audible chime. The chime is a series of 5 sets of 5 tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If 2 or more faults occur at the same time, the fault having the highest priority will be displayed. After that 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 front air bags and safety belt pretensioners in the event that the ignition circuit is lost or damaged during impact. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 9147 Air Bag Control Module: Service and Repair RESTRAINTS CONTROL MODULE (RCM) Vehicles With A Center Console Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 9148 Vehicles With 60/40 Front Bench Seat 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. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - The restraints control module (RCM) orientation is critical for proper air bag supplemental restraint system (SRS) operation. If a vehicle equipped with an SRS system has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the RCM must be replaced whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. - To reduce the risk of personal injury, do not use any memory saver devices. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - When installing a new restraints control module (RCM), always make sure the correct RCM is being installed. If an incorrect RCM is installed, erroneous DTCs will result. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. All vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 9149 1. Depower the system. Vehicles with a center console 2. Remove the center console. Vehicles with 60/40 front bench seat 3. Remove the 60 percent portion of the front bench seat. 4. Remove the 3 nuts and the restraints control module (RCM) top bracket. 5. WARNING: Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. Remove the 3 nuts and separate the RCM from the bracket. All vehicles 6. Disconnect the small restraints control module (RCM) electrical connector. 1 Push down to release the retaining tab. 2 While releasing the retaining tab, pull out and disconnect the small RCM electrical connector. 7. Disconnect the large RCM electrical connector. 1 Pinch the thumb tab and pivot the connector position assurance lever away from the RCM, disengaging the lever. 2 Pull out and disconnect the large RCM electrical connector. Vehicles with 60/40 front bench seat 8. Remove the RCM. Vehicles with a center console 9. Remove the 4 RCM bracket bolts and RCM with the bracket. Installation Vehicles with a center console 1. WARNING: The tightening torque of the air bag restraints control module (RCM) bracket retaining bolts is critical for correct system operation. Position the RCM with bracket and install the 4 bolts. Tighten to 12 Nm (9 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 9150 All vehicles 2. Make sure the connector position assurance lever is in the full release position before attempting to connect the connector. 3. CAUTION: Putting the large RCM electrical connector into the RCM on an angle can cause bad electrical connections and damage components. Position the large RCM electrical connector into the RCM. - CAUTION: Do not push the connector on to where the lever pivots and seats itself. Light pressure is needed to get the connector into position on the RCM before using the lever to fully seat the connector. With the large RCM electrical connector uniformly aligned to the RCM, lightly push in until a subtle audible click is heard and slight resistance is felt. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 9151 4. Connect the RCM electrical connector. - Pivot the connector position assurance lever toward the RCM, drawing the connector in to the RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place. 5. Connect the small RCM electrical connector. Vehicles with 60/40 front bench seat 6. WARNING: The tightening torque of the air bag restraints control module (RCM) to bracket retaining nuts is critical for correct system operation. Position the RCM to the bracket and install the 3 nuts. Tighten to 12 Nm (9 lb-ft). 7. Position the RCM top bracket and install the nuts. - Tighten to 12 Nm (9 lb-ft). Vehicles with a center console 8. Install the center console. Vehicles with 60/40 front bench seat 9. Install the 60 percent portion of the front bench seat. All vehicles 10. Repower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Control Module: > 05-22-17 > Nov > 05 > Restraints - Cannot Disable 'Belt Minder' Chime Seat Belt Control Module: Customer Interest Restraints - Cannot Disable 'Belt Minder' Chime TSB 05-22-17 11/14/05 INABILITY TO DISABLE THE SUPPLEMENTAL SAFETY BELT WARNING CHIME (BELTMINDER) FORD: 2006 Expedition LINCOLN: 2006 Navigator ISSUE Some 2006 Expedition/Navigator vehicles may exhibit an inability to disable the Belt Minder function following procedures listed in the Workshop Manual or the Owner Guide. The Belt Minder function operates normally, but can not be turned off (if desired by the customer). ACTION Replace the restraint control module (RCM), which includes software to disable the Belt Minder. Refer to Workshop Manual, Section 501-20B to replace the RCM. Then follow Workshop Manual, Section 413-09 or the Owner Guide procedure to disable the Belt Minder function. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052217A 2006 Expedition: Replace 1.0 Hrs. The Restraints Control Module Includes Time To Depower And Repower The Supplemental Restraints System And Disable The Beltminder (Do Not Use With 14056D, 14056D1B, 14056D1C, 14056D1XN, 14056DZR) 052217A 2006 Navigator: Replace 1.2 Hrs. The Restraints Control Module Includes Time To Depower And Repower The Supplemental Restraints System And Disable The Beltminder (Do Not Use With 14056D, 14056D1B, 14056D1C, 14056D1XN, 14056DZR) DEALER CODING CONDITION BASIC PART NO. CODE 14B321 42 OASIS CODES: 104000, 206000 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Control Module: > 05-22-17 > Nov > 05 > Restraints - Cannot Disable 'Belt Minder' Chime > Page 9160 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Control Module: > 05-22-17 > Nov > 05 > Restraints - Cannot Disable 'Belt Minder' Chime Seat Belt Control Module: All Technical Service Bulletins Restraints - Cannot Disable 'Belt Minder' Chime TSB 05-22-17 11/14/05 INABILITY TO DISABLE THE SUPPLEMENTAL SAFETY BELT WARNING CHIME (BELTMINDER) FORD: 2006 Expedition LINCOLN: 2006 Navigator ISSUE Some 2006 Expedition/Navigator vehicles may exhibit an inability to disable the Belt Minder function following procedures listed in the Workshop Manual or the Owner Guide. The Belt Minder function operates normally, but can not be turned off (if desired by the customer). ACTION Replace the restraint control module (RCM), which includes software to disable the Belt Minder. Refer to Workshop Manual, Section 501-20B to replace the RCM. Then follow Workshop Manual, Section 413-09 or the Owner Guide procedure to disable the Belt Minder function. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052217A 2006 Expedition: Replace 1.0 Hrs. The Restraints Control Module Includes Time To Depower And Repower The Supplemental Restraints System And Disable The Beltminder (Do Not Use With 14056D, 14056D1B, 14056D1C, 14056D1XN, 14056DZR) 052217A 2006 Navigator: Replace 1.2 Hrs. The Restraints Control Module Includes Time To Depower And Repower The Supplemental Restraints System And Disable The Beltminder (Do Not Use With 14056D, 14056D1B, 14056D1C, 14056D1XN, 14056DZR) DEALER CODING CONDITION BASIC PART NO. CODE 14B321 42 OASIS CODES: 104000, 206000 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Control Module: > 05-22-17 > Nov > 05 > Restraints - Cannot Disable 'Belt Minder' Chime > Page 9166 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Depowering and Repowering SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING Depowering Procedure WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the electrical connector on a safety canopy module. Doing so can result in safety canopy deployment. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the RH side of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse 19 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located at the bottom of the hood latch support bracket. The first row side impact sensors (if equipped) are located in the first row doors, behind the door trim panel. The second row side impact sensors (if equipped) are located at or near the base of the C-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install the RCM fuse 19 (10A) to the CJB and close the cover. 4. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9172 Connect the battery ground cable. 5. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a diagnostic tool. Deactivation and Reactivation SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION Special Tool(s) Special Tool(s) Deactivation WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the connectors on the safety canopy module. Doing so can result in safety canopy module deployment. - To reduce the risk of personal injury, do not use any memory saver devices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9173 NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the RH side of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse 19 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located at the bottom of the hood latch support bracket. The first row side impact sensors (if equipped) are located in the first row doors, behind the door trim panel. The second row side impact sensors (if equipped) are located at or near the base of the C-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 7. Remove the 2 steering wheel back cover plugs (1 shown). 8. Remove the 2 driver air bag module bolts (1 shown). Expedition Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9174 9. Remove the driver air bag module. 1 Release the 2 retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector before disconnecting. 2 Release the 2 retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector before disconnecting. 3 Disconnect the horn switch electrical connector. 4 Remove the driver air bag module. Navigator 10. Disconnect the driver air bag module. - Release the 2 tabs on each driver air bag module electrical connector and disconnect them. Label each driver air bag module electrical connector before disconnecting. 11. Release the tab and disconnect the driver air bag module accessories electrical connector at the top of the clockspring and remove the driver air bag module. All vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9175 12. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of the steering column. 13. While pushing in on the 2 glove compartment door tabs, position the glove compartment downward. 14. NOTE: Expedition shown, Navigator similar. Through the glove compartment opening, release the tab and disconnect the passenger air bag module electrical connector. 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Vehicles with safety canopies Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9176 16. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or if it does not remain closed, install a new shoulder safety belt guide cover. Remove the second row passenger side safety belt guide. 1 Release the retaining tab at each side and open the safety belt guide cover. 2 Remove the nut. 3 Remove the second row passenger side safety belt guide. 17. Remove the passenger side C-pillar trim panel. 1 Separate the weather-stripping along the passenger side C-pillar trim panel. 2 Remove the bolt cover and bolt. 3 Pull out to release the retainers and remove the passenger side C-pillar trim panel. 18. Disconnect the passenger side safety canopy electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9177 19. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy electrical connector. 20. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or if it does not remain closed, install a new shoulder safety belt guide cover. Remove the second row driver side safety belt guide. 1 Release the retaining tab at each side and open the safety belt guide cover. 2 Remove the nut. 3 Remove the second row driver side safety belt guide. 21. Remove the driver side C-pillar trim panel. 1 Separate the weather-stripping along the driver side C-pillar trim panel. 2 Remove the bolt cover and bolt. 3 Pull out to release the retainers and remove the driver side C-pillar trim panel. 22. Disconnect the driver side safety canopy electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9178 23. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy electrical connector. All vehicles 24. Install the RCM fuse 19 (10A) to the CJB. 25. Connect the battery ground cable. Reactivation All vehicles 1. Remove the RCM fuse 19 (10A) from the CJB. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles with safety canopies 3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy electrical connector. 4. Connect the driver side safety canopy electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9179 5. WARNING: Anytime the safety canopy module has deployed, the headliner, and all A, B, and C pillar upper trim panels and attaching hardware must be replaced along with any other damaged components and hardware. Failure to do so may result in personal injury in the event of a safety canopy module deployment. Install the driver side C-pillar trim panel. 1 Position the driver side C-pillar trim panel and push in, engaging the retainers. 2 Install the bolt and bolt cover. Tighten to 11 Nm (8 lb-ft). 3 Install the weather-stripping along the driver side C-pillar trim panel. 6. NOTE: - Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or if it does not remain closed, install a new shoulder safety belt guide cover. - Make sure the safety belt is not twisted prior to installation. Install the second row driver side safety belt guide. 1 Position the second row driver side safety belt guide. 2 Install the nut. Tighten to 40 Nm (30 lb-ft). 3 Close the safety belt guide cover. Verify the safety belt retractor operates without excessive effort or binding. 7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9180 8. Connect the passenger side safety canopy electrical connector. 9. WARNING: Anytime the safety canopy module has deployed, the headliner, and all A, B, and C pillar upper trim panels and attaching hardware must be replaced along with any other damaged components and hardware. Failure to do so may result in personal injury in the event of a safety canopy module deployment. Install the passenger C-pillar trim panel. 1 Position the passenger side C-pillar trim panel and push in, engaging the retainers. 2 Install the bolt and bolt cover. Tighten to 11 Nm (8 lb-ft). 3 Install the weather-stripping along the passenger side C-pillar trim panel. 10. NOTE: - Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or if it does not remain closed, install a new shoulder safety belt guide cover. - Make sure the safety belt is not twisted prior to installation. Install the second row passenger side safety belt guide. 1 Position the second row passenger side safety belt guide. 2 Install the nut. Tighten to 40 Nm (30 lb-ft). 3 Close the safety belt guide cover. Verify the safety belt retractor operates without excessive effort or binding. All vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9181 11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. 12. NOTE: Expedition shown, Navigator similar. Connect the passenger air bag module electrical connector. 13. Close the glove compartment. 14. Remove the restraint system diagnostic tools from the clockspring electrical connector at the top of the steering column. Navigator 15. Connect the driver air bag module accessories electrical connector to the connector end at the top of the clockspring. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9182 16. CAUTION: The clockspring electrical connectors are unique and cannot be reversed when connected to the driver air bag module. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Connect the driver air bag module electrical connectors as noted during removal. Position the driver air bag module to the steering wheel. Expedition 17. Position the driver air bag module to the steering wheel. 1 Connect the horn switch electrical connector. 2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when connected to the driver air bag module. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Connect the driver air bag module electrical connectors as noted during removal. 3 Position the driver air bag module to the steering wheel. All vehicles 18. Install the 2 driver air bag module bolts (1 shown). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9183 19. Install the 2 steering wheel back cover plugs (1 shown). 20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse 19 (10A) to the CJB and close the cover. 23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a diagnostic tool. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9184 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure PROVE OUT PROCEDURE Turn the ignition switch from the OFF to the ON position and visually monitor the air bag indicator with all SRS components connected or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an SRS fault is present, the air bag indicator will: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation Child Seat Tether Attachment: Description and Operation Attaching Safety Seats With Tether Straps Some manufacturers make child safety seats that include a tether strap that goes over the back of the vehicle seat and attaches to an anchoring point. Other manufacturers offer the tether strap as an accessory. Contact the manufacturer of the child safety seat for information about ordering a tether strap. Child safety seat tether anchors are manufactured into the vehicle. See the active restraint system component location at the beginning or the owner's literature for locations. For removal and installation of child safety seat tether anchors, refer to the appropriate procedure or Seats for seat cushion frame replacement. Lower Anchors and Tethers for Children (LATCH) The lower anchors and tethers for children (LATCH) system is a standardized and uniform attachment system for installing child safety seats in passenger vehicles. LATCH-equipped child safety seats have 2 lower attachments that connect to the vehicle portion of the LATCH system. The vehicle portion of the system consists of 2 attachment points (6 mm wires) welded to the rear seat cushion frame. The attachment points protrude from the bite line between the seat cushion and seat backrest. If a child safety seat was in use during a collision, inspect the vehicle portion of the system for damage. If any of the attachment points (6 mm wires) are damaged, install a new seat cushion frame. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation > Page 9189 Child Seat Tether Attachment: Service and Repair CHILD SAFETY SEAT TETHER ANCHOR Removal and Installation WARNING: All safety belt assemblies (including retractors, belt tension sensor [BTS], if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after every collision. All new belt assemblies should be installed unless a qualified technician finds the assemblies show no damage and operate correctly. Belt assemblies not in use during a collision should also be inspected and new assemblies installed if either damage or incorrect operation is noted. Failure to follow these instructions could increase the risk of injury in collisions. 1. Position the third row seat backrest downward. 2. Release the seat back J-clips. 3. With the seat backrest trim cover and cushion positioned aside, remove the nut, bolt and the tether anchor. - To install, tighten to 15 Nm (11 lb-ft). 4. WARNING: It is important that the bolt/anchor be securely tightened to specification. Otherwise, the child's safety seat may not be correctly secured and the child could be injured in case of a sudden stop or accident. NOTE: Inspect the seat for damage. If the seat is found to be damaged, install new seat components. To install, reverse the removal procedure. 5. Check the active restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Description and Operation Seat Belt: Description and Operation FASTENING SAFETY BELTS WARNING: Do not introduce slack into the safety belt system because the belt locks upon impact where it is positioned. Use the shoulder safety belt on the outside shoulder only. Never wear the shoulder safety belt under the arm. Never swing the shoulder safety belt around the neck over the inside shoulder. Never use a single belt for more than one person. Make sure the lap portion of the belt is fitted snugly and as low as possible around the hips, not the waist. Failure to follow these precautions could increase the chance and severity of injury in a collision. Always follow the preceding safety precautions when fastening the safety belts. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Safety Belt Cleaning Seat Belt: Service and Repair Safety Belt Cleaning SAFETY BELT CLEANING 1. WARNING: Do not bleach or re-dye the webbing, as the webbing may weaken. Clean the safety belt webbing only with a mild soap solution recommended for cleaning upholstery or carpets. Follow the instructions provided with the soap. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Safety Belt Cleaning > Page 9195 Seat Belt: Service and Repair Safety Belt Twisted At the Safety Belt Guide - Outboard SAFETY BELT TWISTED AT THE SAFETY BELT GUIDE - OUTBOARD 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 correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Safety Belt Cleaning > Page 9196 Seat Belt: Service and Repair Safety Belt Tongue Rotated on Belt 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. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Safety Belt Cleaning > Page 9197 Seat Belt: Service and Repair Safety Belt - Front, Center SAFETY BELT - FRONT, CENTER Removal and Installation WARNING: All safety belt assemblies (including retractors, belt tension sensor [BTS], if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after every collision. All new belt assemblies should be installed unless a qualified technician finds the assemblies show no damage and operate correctly. Belt assemblies not in use during a collision should also be inspected and new assemblies installed if either damage or incorrect operation is noted. Failure to follow these instructions could increase the risk of injury in collisions. 1. Remove the cover. 2. Remove the bolt and route the safety belt out from the seat. 1 To install, tighten to 43 Nm (32 lb-ft). 3. NOTE: - Make sure the safety belt webbing is not twisted prior to installation. - When installing, make sure the safety belt anchor is on top of the seat bracket. - Make sure the safety belt is accessible to the occupant after installation. To install, reverse the removal procedure. 4. Check the active restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Description and Operation Seat Belt Buckle: Description and Operation SAFETY BELT BUCKLE AND PRETENSIONER NOTE: There is currently no restraint system diagnostic tool for the safety belt buckle pretensioner under the seat connectors. If the ignition switch is turned to the ON or START position with the safety belt buckle pretensioner electrical connector(s) disconnected, the DTC and flagged faults for an open circuit will be activated. The safety belt buckle and pretensioners are for the front outboard occupants, located on the inboard side of the seats. This allows the front safety belt buckle end to move with the front seat. The safety belt buckle and pretensioner is a pyrotechnic device that removes excess webbing from the safety belt system. When the front air bag system is deployed, the pretensioner in the buckle deploys, causing the buckle to move downward, pulling excess webbing from the lap and shoulder safety belts. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Front Center Seat Seat Belt Buckle: Service and Repair Safety Belt Buckle - Front Center Seat SAFETY BELT BUCKLE - FRONT CENTER SEAT Removal and Installation WARNING: All safety belt assemblies (including retractors, belt tension sensor [BTS], if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after every collision. All new belt assemblies should be installed unless a qualified technician finds the assemblies show no damage and operate correctly. Belt assemblies not in use during a collision should also be inspected and new assemblies installed if either damage or incorrect operation is noted. Failure to follow these instructions could increase the risk of injury in collisions. 1. Remove the cover. 2. Remove the bolt and route the safety belt buckle out of the seat. - To install, tighten to 40 Nm (30 lb-ft). 3. NOTE: - Make sure the safety belt webbing is not twisted prior to installation. - Make sure the safety belt buckle is accessible to the occupant after installation. To install, reverse the removal procedure. 4. Check the active restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Front Center Seat > Page 9203 Seat Belt Buckle: Service and Repair Safety Belt Buckle - Second Row, 20 Percent Seat SAFETY BELT BUCKLE - SECOND ROW, 20 PERCENT SEAT Removal and Installation WARNING: All safety belt assemblies (including retractors, belt tension sensor [BTS], if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after every collision. All new belt assemblies should be installed unless a qualified technician finds the assemblies show no damage and operate correctly. Belt assemblies not in use during a collision should also be inspected and new assemblies installed if either damage or incorrect operation is noted. Failure to follow these instructions could increase the risk of injury in collisions. 1. Remove the second row 20 percent seat. 2. NOTE: It may be necessary to fold the seat to remove the side shield. Remove the 2 screws and the pin-type retainer (not shown) and remove the inboard side shield. 3. Remove the nut and the safety belt buckle. - To install, tighten to 40 Nm (30 lb-ft). 4. NOTE: When installing the safety belt buckle, make sure to engage the anti-rotation tab to the seat frame. To install, reverse the removal procedure. 5. Check the active restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Front Center Seat > Page 9204 Seat Belt Buckle: Service and Repair Safety Belt Buckle - Second Row, 40 Percent Seat SAFETY BELT BUCKLE - SECOND ROW, 40 PERCENT SEAT Removal and Installation WARNING: All safety belt assemblies (including retractors, belt tension sensor [BTS], if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after every collision. All new belt assemblies should be installed unless a qualified technician finds the assemblies show no damage and operate correctly. Belt assemblies not in use during a collision should also be inspected and new assemblies installed if either damage or incorrect operation is noted. Failure to follow these instructions could increase the risk of injury in collisions. NOTE: RH 40 percent seat shown, LH similar. 1. Pivot the 40 percent seat upward. 2. Remove the 2 screws and the seat side shield. 3. Remove the screw and the lower pedestal cover. 4. Remove the bolt and the safety belt buckle. - To install, tighten to 40 Nm (30 lb-ft). 5. NOTE: When installing the safety belt buckle, make sure to engage the anti-rotation tab to the seat frame. To install, reverse the removal procedure. 6. Check the active restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Front Center Seat > Page 9205 Seat Belt Buckle: Service and Repair Safety Belt Buckle - Third Row, 40 Percent Seat SAFETY BELT BUCKLE - THIRD ROW, 40 PERCENT SEAT Removal and Installation WARNING: All safety belt assemblies (including retractors, belt tension sensor [BTS], if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after every collision. All new belt assemblies should be installed unless a qualified technician finds the assemblies show no damage and operate correctly. Belt assemblies not in use during a collision should also be inspected and new assemblies installed if either damage or incorrect operation is noted. Failure to follow these instructions could increase the risk of injury in collisions. 1. Remove the third row seat. 2. Remove the bolt and the safety belt buckle. - To install, tighten to 40 Nm (30 lb-ft). 3. NOTE: - When installing the safety belt buckle, make sure to engage the anti-rotation tab to the sheet metal. - Make sure the safety belt buckle is accessible to the passenger after installation. To install, reverse the removal procedure. 4. Check the active restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Front Center Seat > Page 9206 Seat Belt Buckle: Service and Repair Safety Belt Buckle - Front Center Seat SAFETY BELT BUCKLE - FRONT CENTER SEAT Removal and Installation WARNING: All safety belt assemblies (including retractors, belt tension sensor [BTS], if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after every collision. All new belt assemblies should be installed unless a qualified technician finds the assemblies show no damage and operate correctly. Belt assemblies not in use during a collision should also be inspected and new assemblies installed if either damage or incorrect operation is noted. Failure to follow these instructions could increase the risk of injury in collisions. 1. Remove the cover. 2. Remove the bolt and route the safety belt buckle out of the seat. - To install, tighten to 40 Nm (30 lb-ft). 3. NOTE: - Make sure the safety belt webbing is not twisted prior to installation. - Make sure the safety belt buckle is accessible to the occupant after installation. To install, reverse the removal procedure. 4. Check the active restraint system for correct operation. Safety Belt Buckle - Second Row, 20 Percent Seat SAFETY BELT BUCKLE - SECOND ROW, 20 PERCENT SEAT Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Front Center Seat > Page 9207 Removal and Installation WARNING: All safety belt assemblies (including retractors, belt tension sensor [BTS], if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after every collision. All new belt assemblies should be installed unless a qualified technician finds the assemblies show no damage and operate correctly. Belt assemblies not in use during a collision should also be inspected and new assemblies installed if either damage or incorrect operation is noted. Failure to follow these instructions could increase the risk of injury in collisions. 1. Remove the second row 20 percent seat. 2. NOTE: It may be necessary to fold the seat to remove the side shield. Remove the 2 screws and the pin-type retainer (not shown) and remove the inboard side shield. 3. Remove the nut and the safety belt buckle. - To install, tighten to 40 Nm (30 lb-ft). 4. NOTE: When installing the safety belt buckle, make sure to engage the anti-rotation tab to the seat frame. To install, reverse the removal procedure. 5. Check the active restraint system for correct operation. Safety Belt Buckle - Second Row, 40 Percent Seat SAFETY BELT BUCKLE - SECOND ROW, 40 PERCENT SEAT Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Front Center Seat > Page 9208 Removal and Installation WARNING: All safety belt assemblies (including retractors, belt tension sensor [BTS], if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after every collision. All new belt assemblies should be installed unless a qualified technician finds the assemblies show no damage and operate correctly. Belt assemblies not in use during a collision should also be inspected and new assemblies installed if either damage or incorrect operation is noted. Failure to follow these instructions could increase the risk of injury in collisions. NOTE: RH 40 percent seat shown, LH similar. 1. Pivot the 40 percent seat upward. 2. Remove the 2 screws and the seat side shield. 3. Remove the screw and the lower pedestal cover. 4. Remove the bolt and the safety belt buckle. - To install, tighten to 40 Nm (30 lb-ft). 5. NOTE: When installing the safety belt buckle, make sure to engage the anti-rotation tab to the seat frame. To install, reverse the removal procedure. 6. Check the active restraint system for correct operation. Safety Belt Buckle - Third Row, 40 Percent Seat SAFETY BELT BUCKLE - THIRD ROW, 40 PERCENT SEAT Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Front Center Seat > Page 9209 Removal and Installation WARNING: All safety belt assemblies (including retractors, belt tension sensor [BTS], if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after every collision. All new belt assemblies should be installed unless a qualified technician finds the assemblies show no damage and operate correctly. Belt assemblies not in use during a collision should also be inspected and new assemblies installed if either damage or incorrect operation is noted. Failure to follow these instructions could increase the risk of injury in collisions. 1. Remove the third row seat. 2. Remove the bolt and the safety belt buckle. - To install, tighten to 40 Nm (30 lb-ft). 3. NOTE: - When installing the safety belt buckle, make sure to engage the anti-rotation tab to the sheet metal. - Make sure the safety belt buckle is accessible to the passenger after installation. To install, reverse the removal procedure. 4. Check the active restraint system for correct operation. Safety Belt Buckle - Third Row, 60 Percent Seat SAFETY BELT BUCKLE - THIRD ROW, 60 PERCENT SEAT Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Front Center Seat > Page 9210 Removal and Installation WARNING: All safety belt assemblies (including retractors, belt tension sensor [BTS], if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after every collision. All new belt assemblies should be installed unless a qualified technician finds the assemblies show no damage and operate correctly. Belt assemblies not in use during a collision should also be inspected and new assemblies installed if either damage or incorrect operation is noted. Failure to follow these instructions could increase the risk of injury in collisions. 1. Remove the rear load floor panel. 2. Remove the mid-floor panel support. - Remove the jack assembly. - Remove the 2 pin-type retainers (not shown). - Remove the 2 bolts. - Position the load floor panels up, lift on the front of the mid-floor panel support to release the 3 retaining clips (not shown) and remove the support panel. 3. Remove the bolt and the safety belt buckle assembly. - To install, tighten to 40 Nm (30 lb-ft). 4. NOTE: - When installing the safety belt buckle assembly, make sure to engage the anti-rotation tab to the sheet metal. - Make sure the safety belt buckles are accessible to the passengers after installation. To install, reverse the removal procedure. 5. Check the active restraint system for correct operation. 40 Percent Seat Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Front Center Seat > Page 9211 SAFETY BELT BUCKLE AND PRETENSIONER - 40 PERCENT SEAT Removal and Installation WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. - All safety belt assemblies (including retractors, belt tension sensor [BTS], if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after every collision. All new belt assemblies should be installed unless a qualified technician finds the assemblies show no damage and operate correctly. Belt assemblies not in use during a collision should also be inspected and new assemblies installed if either damage or incorrect operation is noted. Failure to follow these instructions could increase the risk of injury in collisions. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - LH shown, RH similar. 1. Position the seat to gain access to all seat fasteners. 2. Depower the SRS. 3. Remove the 40 percent front seat. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Front Center Seat > Page 9212 4. Release the hook-and-loop strip and pull the seat cushion trim cover up enough to expose the safety belt buckle and pretensioner. 5. NOTE: Make note of the wire harness routing for installation. Remove the safety belt buckle and pretensioner electrical connectors from the seat cushion frame. Disconnect the usage detection switch electrical connector. - Separate the safety belt buckle pretensioner electrical connector from the pin-type retainer. 6. Remove the nut and the safety belt buckle and pretensioner. - To install, tighten to 40 Nm (30 lb-ft). 7. To install, reverse the removal procedure. 8. Install the 40 percent front seat. 9. Repower the SRS. 10. Check the active restraint system for correct operation. 60 Percent Seat SAFETY BELT BUCKLE AND PRETENSIONER - 60 PERCENT SEAT Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Front Center Seat > Page 9213 Removal WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. - All safety belt assemblies (including retractors, belt tension sensor [BTS], if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after every collision. All new belt assemblies should be installed unless a qualified technician finds the assemblies show no damage and operate correctly. Belt assemblies not in use during a collision should also be inspected and new assemblies installed if either damage or incorrect operation is noted. Failure to follow these instructions could increase the risk of injury in collisions. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Position the seat to gain access to all seat fasteners. 2. Depower the SRS. 3. Remove the 60 percent front seat. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Front Center Seat > Page 9214 4. NOTE: Make note of the wire harness routing for installation. Detach the electrical connectors and route out the wire harnesses. 5. Remove the nut and the safety belt buckle pretensioner assembly. Installation 1. Install the safety belt buckle and pretensioner. 1 Position the safety belt buckle and pretensioner to the seat. Align the safety belt buckle and pretensioner locator tab to the hole in the seat frame. - Check that the safety belt buckle end is accessible after positioning. 2 Install the nut. Tighten to 40 Nm (30 lb-ft). 3 Route the safety belt buckle and pretensioner usage detection switch and pretensioner electrical connectors as noted in removal. 2. Attach the electrical connectors and route the wire harnesses as noted in removal. 3. Install the 60 percent front seat. 4. Repower the SRS. 5. Check the active restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger View 151-17 (RH A-Pillar) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger > Page 9219 View 151-26 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver C3065 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver > Page 9222 C3066 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Page 9223 Seat Belt Buckle Switch: Description and Operation SAFETY BELT BUCKLE SWITCHES As part of the supplemental restraint system (SRS), the driver and front outboard passenger safety belt buckles are equipped with safety belt buckle switches. The safety belt buckle switches indicate to the restraints control module (RCM) whether the safety belts are connected or disconnected. The RCM uses this information in determining the deployment rate of the dual-stage driver and passenger air bag modules. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Control Module: > 05-22-17 > Nov > 05 > Restraints - Cannot Disable 'Belt Minder' Chime Seat Belt Control Module: Customer Interest Restraints - Cannot Disable 'Belt Minder' Chime TSB 05-22-17 11/14/05 INABILITY TO DISABLE THE SUPPLEMENTAL SAFETY BELT WARNING CHIME (BELTMINDER) FORD: 2006 Expedition LINCOLN: 2006 Navigator ISSUE Some 2006 Expedition/Navigator vehicles may exhibit an inability to disable the Belt Minder function following procedures listed in the Workshop Manual or the Owner Guide. The Belt Minder function operates normally, but can not be turned off (if desired by the customer). ACTION Replace the restraint control module (RCM), which includes software to disable the Belt Minder. Refer to Workshop Manual, Section 501-20B to replace the RCM. Then follow Workshop Manual, Section 413-09 or the Owner Guide procedure to disable the Belt Minder function. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052217A 2006 Expedition: Replace 1.0 Hrs. The Restraints Control Module Includes Time To Depower And Repower The Supplemental Restraints System And Disable The Beltminder (Do Not Use With 14056D, 14056D1B, 14056D1C, 14056D1XN, 14056DZR) 052217A 2006 Navigator: Replace 1.2 Hrs. The Restraints Control Module Includes Time To Depower And Repower The Supplemental Restraints System And Disable The Beltminder (Do Not Use With 14056D, 14056D1B, 14056D1C, 14056D1XN, 14056DZR) DEALER CODING CONDITION BASIC PART NO. CODE 14B321 42 OASIS CODES: 104000, 206000 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Control Module: > 05-22-17 > Nov > 05 > Restraints - Cannot Disable 'Belt Minder' Chime > Page 9232 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Control Module: > 05-22-17 > Nov > 05 > Restraints - Cannot Disable 'Belt Minder' Chime Seat Belt Control Module: All Technical Service Bulletins Restraints - Cannot Disable 'Belt Minder' Chime TSB 05-22-17 11/14/05 INABILITY TO DISABLE THE SUPPLEMENTAL SAFETY BELT WARNING CHIME (BELTMINDER) FORD: 2006 Expedition LINCOLN: 2006 Navigator ISSUE Some 2006 Expedition/Navigator vehicles may exhibit an inability to disable the Belt Minder function following procedures listed in the Workshop Manual or the Owner Guide. The Belt Minder function operates normally, but can not be turned off (if desired by the customer). ACTION Replace the restraint control module (RCM), which includes software to disable the Belt Minder. Refer to Workshop Manual, Section 501-20B to replace the RCM. Then follow Workshop Manual, Section 413-09 or the Owner Guide procedure to disable the Belt Minder function. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052217A 2006 Expedition: Replace 1.0 Hrs. The Restraints Control Module Includes Time To Depower And Repower The Supplemental Restraints System And Disable The Beltminder (Do Not Use With 14056D, 14056D1B, 14056D1C, 14056D1XN, 14056DZR) 052217A 2006 Navigator: Replace 1.2 Hrs. The Restraints Control Module Includes Time To Depower And Repower The Supplemental Restraints System And Disable The Beltminder (Do Not Use With 14056D, 14056D1B, 14056D1C, 14056D1XN, 14056DZR) DEALER CODING CONDITION BASIC PART NO. CODE 14B321 42 OASIS CODES: 104000, 206000 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Control Module: > 05-22-17 > Nov > 05 > Restraints - Cannot Disable 'Belt Minder' Chime > Page 9238 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information > Description and Operation Seat Belt Extension: Description and Operation SAFETY BELT EXTENSION ASSEMBLY In certain cases, the safety belt may be too short, even when it is fully extended. About 20 cm (8 in) can be added to the belt length by using a safety belt extension. Safety belt extensions are available through any Ford or Lincoln Mercury dealer parts department at no cost. Safety belt extensions are only available with black webbing. There are 2 extension assemblies available, one for the front seating positions and one for the rear seating positions. They are not interchangeable. Only use 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 the extension to change the fit of the shoulder belt across the torso. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Safety Belt Shoulder Height Adjuster With Stripped Weld Nuts Seat Belt Height Adjuster: Service and Repair Safety Belt Shoulder Height Adjuster With Stripped Weld Nuts SAFETY BELT SHOULDER HEIGHT ADJUSTER WITH STRIPPED WELD NUTS 1. Remove the B-pillar trim panel. 2. Use the half-inch drill with integral stop to drill out the damaged threads in the upper pillar structure. 3. NOTE: After each rotation, back off tap slightly to remove new cuttings and be sure to blow out any chips before proceeding. Apply a suitable lubricant to the M14 x 1.5 tap with integral stop and tap new threads. 4. Use a threaded insert and screw it into the retapped hole until it is slightly below the surface. 5. Use a hammer to lightly tap the installation tool several times to seat the insert keys. 6. If the bolt(s) on the height adjuster is not stripped, reinstall the original safety belt shoulder height adjuster. If the bolt(s) is stripped, install a new Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Safety Belt Shoulder Height Adjuster With Stripped Weld Nuts > Page 9246 safety belt shoulder height adjuster. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Safety Belt Shoulder Height Adjuster With Stripped Weld Nuts > Page 9247 Seat Belt Height Adjuster: Service and Repair Safety Belt Shoulder Height Adjuster - Front Row SAFETY BELT SHOULDER HEIGHT ADJUSTER - FRONT ROW Removal and Installation WARNING: All safety belt assemblies (including retractors, belt tension sensor [BTS], if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after every collision. All new belt assemblies should be installed unless a qualified technician finds the assemblies show no damage and operate correctly. Belt assemblies not in use during a collision should also be inspected and new assemblies installed if either damage or incorrect operation is noted. Failure to follow these instructions could increase the risk of injury in collisions. NOTE: RH shown, LH similar. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Safety Belt Shoulder Height Adjuster With Stripped Weld Nuts > Page 9248 1. NOTE: - Position the safety belt guide to the lowest position. - Inspect the D-ring cover for damage. If the cover is damaged or does not remain closed install a new D-ring cover. Open the D-ring cover. 2. Remove the nut and the D-ring. - To install, tighten to 40 Nm (30 lb-ft). 3. Remove the upper B-pillar trim panel. - Remove the bolt cover and the bolt. To install, tighten to 8 Nm (11 lb-ft). - Release the clips and slide the upper B-pillar panel downward. 4. Remove the safety belt shoulder height adjuster trim cover. 5. Remove the 2 bolts and the safety belt shoulder height adjuster. - To install, tighten to 40 Nm (30 lb-ft). 6. NOTE: - Make sure the safety belt webbing is not twisted prior to installation. - When installing the upper B-pillar trim panel, insert the safety belt guide slide into the upper B-pillar trim panel. To install, reverse the removal procedure. 7. Check the active restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Safety Belt Shoulder Height Adjuster With Stripped Weld Nuts > Page 9249 Seat Belt Height Adjuster: Service and Repair Safety Belt Shoulder Height Adjuster - Second Row SAFETY BELT SHOULDER HEIGHT ADJUSTER - SECOND ROW Removal and Installation WARNING: All safety belt assemblies (including retractors, belt tension sensor [BTS], if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after every collision. All new belt assemblies should be installed unless a qualified technician finds the assemblies show no damage and operate correctly. Belt assemblies not in use during a collision should also be inspected and new assemblies installed if either damage or incorrect operation is noted. Failure to follow these instructions could increase the risk of injury in collisions. NOTE: RH shown, LH similar. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Safety Belt Shoulder Height Adjuster With Stripped Weld Nuts > Page 9250 1. NOTE: Inspect the D-ring cover for damage. If the cover is damaged or does not remain closed, install a new D-ring cover. Open the D-ring cover. 2. Remove the nut and the D-ring. - To install, tighten to 40 Nm (30 lb-ft). 3. Remove the C-pillar trim panel. - Separate the weatherstripping along the C-pillar trim panel. - Remove the bolt cover and bolt. To install, tighten to 8 Nm (11 lb-ft). - Pull out to release the retainers and remove the C-pillar trim panel. 4. Remove the safety belt height adjuster cover. 5. Remove the 2 bolts and the safety belt shoulder height adjuster. - To install, tighten to 40 Nm (30 lb-ft). 6. NOTE: Make sure the safety belt webbing is not twisted prior to installation. To install, reverse the removal procedure. 7. Check the active restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Description and Operation Seat Belt Reminder Buzzer: Description and Operation Warning System - Driver Safety Belt The driver safety belt incorporates a safety belt warning indicator switch, warning indicator and chime. The warning indicator and chime are reminders to fasten the safety belt. If the driver safety belt is not buckled before the ignition key is turned to ON, the safety belt warning light illuminates for 1 to 2 minutes and the warning chime sounds for 4 to 8 seconds. - If the driver side safety belt is buckled while the indicator light is illuminated and the warning chime is sounding, the safety belt warning light and warning chime turn OFF. - If the safety belt is buckled before the key is turned to the ON position, the warning indicator will come on for 4 to 8 seconds with no chime. Belt Minder (if equipped) The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning lamp in the instrument cluster. To activate or deactivate the Belt Minder feature, refer to Seat Belt Systems or the owner's literature. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation Warning System - Driver Safety Belt The driver safety belt incorporates a safety belt warning indicator switch, warning indicator and chime. The warning indicator and chime are reminders to fasten the safety belt. If the driver safety belt is not buckled before the ignition key is turned to ON, the safety belt warning light illuminates for 1 to 2 minutes and the warning chime sounds for 4 to 8 seconds. - If the driver side safety belt is buckled while the indicator light is illuminated and the warning chime is sounding, the safety belt warning light and warning chime turn OFF. - If the safety belt is buckled before the key is turned to the ON position, the warning indicator will come on for 4 to 8 seconds with no chime. Belt Minder (if equipped) The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning lamp in the instrument cluster. To activate or deactivate the Belt Minder feature, refer to Seat Belt Systems or the owner's literature. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints - Seat Belts Slow to Retract Seat Belt Retractor: Customer Interest Restraints - Seat Belts Slow to Retract TSB 05-16-11 08/22/05 SAFETY BELT RETRACTION SPEED FORD: 2000-2003 Mustang 2000-2006 Crown Victoria, Taurus 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion, Explorer 2000-2006 E-Series, Expedition, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2004-2006 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 LS, Town Car, Navigator 2003-2005 Aviator MERCURY: 2000-2005 Sable 2000-2006 Grand Marquis 2000-2005 Mountaineer 2004-2006 Monterey 2005-2006 Mariner This article supersedes TSB 04-24-21 to update the vehicle model years. ISSUE A service kit is now available to improve safety belt retraction speed. ACTION See the part application chart and select the appropriate kit. Follow the Instruction Sheet included in the kit. Refer to Workshop Manual Section 501-20A for additional information. NOTE TEFLON TAPE SHOULD ONLY BE USED ON THE FRONT ROW SEATS FOR VEHICLES LISTED IN THIS TSB, WITH THE EXCEPTION OF THE AVIATOR, EXPLORER 4DR AND THE MOUNTAINEER. TEFLON TAPE CAN ALSO BE USED ON SECOND ROW SEATS FOR THESE THREE VEHICLES. NOTE FOR MUSTANG, AVIATOR, EXPLORER 4DR AND MOUNTAINEER, REFER TO THE FOLLOWING BUILD DATE INFORMATION BEFORE PERFORMING THIS TSB. TEFLON TAPE HAS ALREADY BEEN INSTALLED DURING PRODUCTION ON SOME OF THESE VEHICLES. ^ MUSTANG: Only install on vehicles built through 6/15/2003. Teflon tape was already installed on vehicles built on/after 6/16/2003. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (FRONT ROW SEATS): Only install on vehicles built through 6/24/2004. Teflon tape was already installed on vehicles built on/after 6/25/2004. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (SECOND ROW SEATS): Only install on vehicles built through 10/21/2004. Teflon tape was already installed on vehicles built on/after 10/22/2004. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints - Seat Belts Slow to Retract > Page 9265 Parts Block NOTE THE LABOR OPERATIONS WITHIN THIS TSB CAN BE CLAIMED IN COMBINATION AS NEEDED TO COVER THE REQUIRED REPAIRS. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051611A Install Teflon Tape B 0.8 Hr. Pillars Both Sides (Includes Time To Remove And Install Trim Panels If Necessary) 051611B Install Teflon Tape C 1.1 Hrs. Pillars Both Sides (Includes Time To Remove And Install Trim Panels And Seats If Necessary) DEALER CODING CONDITION BASIC PART NO. CODE 70611B08 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints Seat Belts Slow to Retract Seat Belt Retractor: All Technical Service Bulletins Restraints - Seat Belts Slow to Retract TSB 05-16-11 08/22/05 SAFETY BELT RETRACTION SPEED FORD: 2000-2003 Mustang 2000-2006 Crown Victoria, Taurus 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion, Explorer 2000-2006 E-Series, Expedition, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2004-2006 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 LS, Town Car, Navigator 2003-2005 Aviator MERCURY: 2000-2005 Sable 2000-2006 Grand Marquis 2000-2005 Mountaineer 2004-2006 Monterey 2005-2006 Mariner This article supersedes TSB 04-24-21 to update the vehicle model years. ISSUE A service kit is now available to improve safety belt retraction speed. ACTION See the part application chart and select the appropriate kit. Follow the Instruction Sheet included in the kit. Refer to Workshop Manual Section 501-20A for additional information. NOTE TEFLON TAPE SHOULD ONLY BE USED ON THE FRONT ROW SEATS FOR VEHICLES LISTED IN THIS TSB, WITH THE EXCEPTION OF THE AVIATOR, EXPLORER 4DR AND THE MOUNTAINEER. TEFLON TAPE CAN ALSO BE USED ON SECOND ROW SEATS FOR THESE THREE VEHICLES. NOTE FOR MUSTANG, AVIATOR, EXPLORER 4DR AND MOUNTAINEER, REFER TO THE FOLLOWING BUILD DATE INFORMATION BEFORE PERFORMING THIS TSB. TEFLON TAPE HAS ALREADY BEEN INSTALLED DURING PRODUCTION ON SOME OF THESE VEHICLES. ^ MUSTANG: Only install on vehicles built through 6/15/2003. Teflon tape was already installed on vehicles built on/after 6/16/2003. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (FRONT ROW SEATS): Only install on vehicles built through 6/24/2004. Teflon tape was already installed on vehicles built on/after 6/25/2004. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (SECOND ROW SEATS): Only install on vehicles built through 10/21/2004. Teflon tape was already installed on vehicles built on/after 10/22/2004. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints Seat Belts Slow to Retract > Page 9271 Parts Block NOTE THE LABOR OPERATIONS WITHIN THIS TSB CAN BE CLAIMED IN COMBINATION AS NEEDED TO COVER THE REQUIRED REPAIRS. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051611A Install Teflon Tape B 0.8 Hr. Pillars Both Sides (Includes Time To Remove And Install Trim Panels If Necessary) 051611B Install Teflon Tape C 1.1 Hrs. Pillars Both Sides (Includes Time To Remove And Install Trim Panels And Seats If Necessary) DEALER CODING CONDITION BASIC PART NO. CODE 70611B08 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Page 9272 Seat Belt Retractor: Description and Operation Dual Locking Mode Retractors WARNING: After any vehicle collision, the safety belt system at all outboard seating positions (except driver, which has no "automatic locking retractor" feature) must be checked by a qualified technician to verify that the "automatic locking retractor" feature for child seats is still functioning correctly, in addition to other checks for correct safety belt system function. A new belt and retractor assembly must be installed if the safety belt assembly's "automatic locking retractor" feature or any other safety belt function is not operating correctly when checked according to the procedures. Failure to install a new Belt and Retractor assembly could increase the risk of injury in collisions. NOTE: When replacing a dual locking mode retractor, the retractor should be checked to make sure it is not in the automatic locking retractor (ALR) mode after installation in the stowed position. All outboard continuous-loop, 3-point retractor systems, except the driver position, are equipped with the dual locking mode system. The emergency locking retractor (ELR) mode will allow the occupant freedom of movement, locking tight only on hard braking, hard cornering, or an impact of approximately 8 km/h (5 mph). The ELR mode helps to reduce the forward movement of the driver and passengers. The ELR mode is continuously in operation at all seating positions. The ALR portion of this system does not allow the occupant freedom of movement. The ALR mode is used when locking a child seat in at a seating position or when a tight belt fit is desired. The ALR mode is automatically engaged when the webbing is fully extracted from the retractor and then allowed to retract. As the webbing is retracted back onto the spool, an audible clicking sound is made, indicating that the retractor is in ALR mode. The ALR mode is automatically disengaged when most of the webbing is retracted back onto the spool. The automatic locking mode must be used when installing a child safety seat in the front or rear passenger seating positions where dual locking mode retractors are provided. Energy Management Retractor This vehicle has a safety belt system with an energy management feature at the front seating positions to help further reduce the risk of injury in the event of a head-on collision. The energy management retractor feature is designed to pay out webbing in a controlled manner. This feature is designed to help reduce the belt force acting on the occupant's chest. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Second Row and Third Row, Outboard Seat Belt Retractor: Service and Repair Safety Belt Retractor - Second Row and Third Row, Outboard SAFETY BELT RETRACTOR - SECOND ROW AND THIRD ROW, OUTBOARD Removal and Installation WARNING: All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after any collision. All new belt assemblies should be installed unless a qualified technician finds the assemblies show no damage and operate correctly. Belt assemblies not in use during a collision should also be inspected and new assemblies installed if either damage or incorrect operation is noted. The automatic locking retractor (ALR) feature of the safety belt retractor must be checked by a qualified technician to verify that the ALR feature for a child safety seat is functioning correctly, in addition to other checks for correct safety belt system function. A new belt and retractor assembly must be installed if the safety belt assembly's "automatic locking retractor" feature or any other safety belt function is not operating correctly when inspected according to the functional inspection procedures. Failure to install a new belt and retractor assembly could increase the risk of injury in collisions. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Second Row and Third Row, Outboard > Page 9275 NOTE: RH shown, LH similar. Both retractors 1. Remove the rear quarter trim panel. Second row retractor 2. Remove the bolt and the safety belt retractor. - To install, tighten to 40 Nm (30 lb-ft). Third row retractor 3. Remove the bolt and the safety belt retractor. - To install, tighten to 40 Nm (30 lb-ft). Both retractors 4. NOTE: - Make sure the safety belt webbing is not twisted prior to installation. - Before installing the third row safety belt anchor, make sure the floor slotted plastic insert is still present. If it is not, another insert must be installed. - When installing the safety belt retractor, make sure to engage the anti-rotation tab to the sheet metal. To install, reverse the removal procedure. 5. Check the active restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Second Row and Third Row, Outboard > Page 9276 Seat Belt Retractor: Service and Repair Rear Center Safety Belt Retractor - Second Row REAR CENTER SAFETY BELT RETRACTOR - SECOND ROW Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Second Row and Third Row, Outboard > Page 9277 Part 2 Removal and Installation WARNING: All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after any collision. All new belt assemblies should be installed unless a qualified technician finds the assemblies show no damage and operate correctly. Belt assemblies not in use during a collision should also be inspected and new assemblies installed if either damage or incorrect operation is noted. The automatic locking retractor (ALR) feature of the safety belt retractor must be checked by a qualified technician to verify that the ALR feature for a child safety seat is functioning correctly, in addition to other checks for correct safety belt system function. A new belt and retractor assembly must be installed if the safety belt assembly's "automatic locking retractor" feature or any other safety belt function is not operating correctly when inspected according to the functional inspection procedures. Failure to install a new belt and retractor assembly could increase the risk of injury in collisions. NOTE: The retractor may be equipped with an additional web stop button (small, thin, round button, not to be confused with the larger web stop button) located on the safety belt webbing. This button is only used for vehicle assembly and serves no other functional purpose. The button can possibly be retracted under the trim bezel making it difficult to pull the safety belt webbing out of the retractor. To service, remove this web stop button. Do not install a new safety belt retractor to eliminate this condition. Any resulting appearance concerns with the webbing can be worked out by hand. 1. Remove the second row 20 percent seat. 2. Remove the 2 screws on the inside of the RH side shield. 3. Release the pin-type retainer and remove the RH side shields. 4. Remove the 2 screws on the inside of the LH side shield. 5. Release the pin-type retainer and remove the LH side shields. 6. Remove the screw and the left hinge side shield. 7. Unsnap the recliner pull strap handle and pull the handle through the seat. 8. Remove the bolt and the safety belt retractor anchor. - To install, tighten to 40 Nm (30 lb-ft). 9. Release the J-clip. 10. Remove the screw from the seat backrest support panel and release the J-clips under the seat backrest support panel. 11. Remove the safety belt guide cover. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Second Row and Third Row, Outboard > Page 9278 12. Invert the seat backrest cover and remove the 2 pin-type retainers. 13. CAUTION: Use care when separating the seat backrest trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat backrest foam. Remove the seat backrest cover. 14. Remove the seat backrest foam pad. 15. Remove the 6 seat backrest support panel screws. 16. Remove the 2 safety belt retractor cover screws and remove the cover. 17. Remove the safety belt retractor bolt. - To install, tighten to 40 Nm (30 lb-ft). 18. Pinch and release the safety belt retractor guide from the seat backrest frame and remove the safety belt retractor. 19. NOTE: - Make sure the safety belt webbing is not twisted prior to installation. - When installing the safety belt retractor, make sure to engage the anti-rotation tab to the sheet metal. - Remove the shipping clip after safety belt retractor installation. To install, reverse the removal procedure. 20. Check the active restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Second Row and Third Row, Outboard > Page 9279 Seat Belt Retractor: Service and Repair Rear Center Safety Belt Retractor - Third Row REAR CENTER SAFETY BELT RETRACTOR - THIRD ROW Removal and Installation WARNING: All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after any collision. All new belt assemblies should be installed unless a qualified technician finds the assemblies show no damage and operate correctly. Belt assemblies not in use during a collision should also be inspected and new assemblies installed if either damage or incorrect operation is noted. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Second Row and Third Row, Outboard > Page 9280 The automatic locking retractor (ALR) feature of the safety belt retractor must be checked by a qualified technician to verify that the ALR feature for a child safety seat is functioning correctly, in addition to other checks for correct safety belt system function. A new belt and retractor assembly must be installed if the safety belt assembly's "automatic locking retractor" feature or any other safety belt function is not operating correctly when inspected according to the functional inspection procedures. Failure to install a new belt and retractor assembly could increase the risk of injury in collisions. NOTE: The retractor may be equipped with an additional web stop button (small, thin, round button, not to be confused with the larger web stop button) located on the safety belt webbing. This button is only used for vehicle assembly and serves no other functional purpose. The button can possibly be retracted under the trim bezel making it difficult to pull the safety belt webbing out of the retractor. To service, remove this web stop button. Do not install a new safety belt retractor to eliminate this condition. Any resulting appearance concerns with the webbing can be worked out by hand. All seats 1. Remove the third row 60 percent seat backrest. 2. Remove the safety belt anchor bolt. - To install, tighten to 40 Nm (30 lb-ft). 3. Depress the tab and remove the head restraint. 4. Release the J-clip. 5. Release the 2 J-clips. Manual seat 6. Remove the 2 seat backrest release handle screws and remove the handle and cable assembly. All seats 7. Remove the safety belt guide. 8. NOTE: The head restraint sleeve pins are not interchangeable, note location for installation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Second Row and Third Row, Outboard > Page 9281 Reach up into the seat backrest, squeeze, release and remove the head restraint sleeves. 9. CAUTION: Use care when separating the seat backrest trim cover from the hook-and-loop strip or the hook-and-loop strip can be torn from the seat backrest foam. Invert the seat backrest trim cover and remove. 10. Remove the seat backrest foam pad. 11. Remove the 4 screws from the seat belt cover (2 shown). 12. Remove the safety belt retractor bolt. - To install, tighten to 40 Nm (30 lb-ft). 13. Pinch to release the safety belt guide and remove the safety belt retractor. 14. NOTE: - Make sure the safety belt webbing is not twisted prior to installation. - Remove the shipping clip after safety belt retractor installation. To install, reverse the removal procedure. 15. Check the active restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Second Row and Third Row, Outboard > Page 9282 Seat Belt Retractor: Service and Repair Safety Belt Retractor - Front SAFETY BELT RETRACTOR - FRONT Removal and Installation WARNING: All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after any collision. All new belt assemblies should be installed unless a qualified technician finds the assemblies show no damage and operate correctly. Belt assemblies not in use during a collision should also be inspected and new assemblies installed if either damage or incorrect operation is noted. The automatic locking retractor (ALR) feature of the safety belt retractor must be checked by a qualified technician to verify that the ALR feature for a child safety seat is functioning correctly, in addition to other checks for correct safety belt system function. A new belt and retractor assembly must be installed if the safety belt assembly's ■automatic locking retractor" feature or any other safety belt function is not operating correctly when inspected according to the functional inspection procedures. Failure to install a new belt and retractor assembly could increase the risk of injury in collisions. NOTE: RH shown, LH similar. 1. Remove the B-pillar trim panel. 2. Release the 2 pin-type retainers and the safety belt guide. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Second Row and Third Row, Outboard > Page 9283 3. Remove the 3 bolts and the B-pillar trim panel bracket. 4. Remove the bolt and the safety belt retractor. - To install, tighten to 40 Nm (30 lb-ft). 5. NOTE: - Make sure the safety belt webbing is not twisted prior to installation. - When installing the safety belt retractor, make sure to engage the anti-rotation tab to the sheet metal - Remove the shipping clip after safety belt retractor installation. To install, reverse the removal procedure. 6. Check the active restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Safety Belt Pretensioner, Driver C3201 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Safety Belt Pretensioner, Driver > Page 9288 C3202 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Safety Belt System Seat Belt Tensioner: Description and Operation Safety Belt System Pretensioner System All vehicles have a pretensioner system used with the front outboard safety belt buckles. This works in conjunction with the front air bag system mounted in the steering wheel and instrument panel. If the vehicle is involved in a collision that results in deployment of the front air bags and safety belt pretensioners, the driver and passenger seat belt system (including safety belt buckle and pretensioners, safety belt retractors and height adjusters) must be replaced. For diagnostic information, refer to Air Bag Systems. For pretensioner buckle disposal information, refer to Air Bag Systems. Safety Belt Buckle And Pretensioner NOTE: There is currently no restraint system diagnostic tool for the safety belt buckle pretensioner under the seat connectors. If the ignition switch is turned to the ON or START position with the safety belt buckle pretensioner electrical connector(s) disconnected, the DTC and flagged faults for an open circuit will be activated. The safety belt buckle and pretensioners are for the front outboard occupants, located on the inboard side of the seats. This allows the front safety belt buckle end to move with the front seat. The safety belt buckle and pretensioner is a pyrotechnic device that removes excess webbing from the safety belt system. When the front air bag system is deployed, the pretensioner in the buckle deploys, causing the buckle to move downward, pulling excess webbing from the lap and shoulder safety belts. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Safety Belt System > Page 9291 Seat Belt Tensioner: Description and Operation Supplemental Restraint System SAFETY BELT PRETENSIONERS NOTE: There is currently no restraint system diagnostic tool for the safety belt buckle pretensioner under the seat connectors. When diagnosing the safety belt buckle pretensioners, it will be necessary to disconnect the affected safety belt buckle pretensioner pigtail harness connector on the component and install a restraint system diagnostic tool. As part of the SRS, the driver and front outboard passenger safety belt buckles are equipped with pretensioners. The safety belt buckle pretensioners remove excess slack from the safety belt webbing. The pretensioners are activated by the restraints control module (RCM) when the module detects a crash event force exceeding a programmed limit. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner Seat Belt Tensioner: Service and Repair Safety Belt Buckle and Pretensioner 40 Percent Seat SAFETY BELT BUCKLE AND PRETENSIONER - 40 PERCENT SEAT Removal and Installation WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. - All safety belt assemblies (including retractors, belt tension sensor [BTS], if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after every collision. All new belt assemblies should be installed unless a qualified technician finds the assemblies show no damage and operate correctly. Belt assemblies not in use during a collision should also be inspected and new assemblies installed if either damage or incorrect operation is noted. Failure to follow these instructions could increase the risk of injury in collisions. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - LH shown, RH similar. 1. Position the seat to gain access to all seat fasteners. 2. Depower the SRS. 3. Remove the 40 percent front seat. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner > Page 9294 4. Release the hook-and-loop strip and pull the seat cushion trim cover up enough to expose the safety belt buckle and pretensioner. 5. NOTE: Make note of the wire harness routing for installation. Remove the safety belt buckle and pretensioner electrical connectors from the seat cushion frame. Disconnect the usage detection switch electrical connector. - Separate the safety belt buckle pretensioner electrical connector from the pin-type retainer. 6. Remove the nut and the safety belt buckle and pretensioner. - To install, tighten to 40 Nm (30 lb-ft). 7. To install, reverse the removal procedure. 8. Install the 40 percent front seat. 9. Repower the SRS. 10. Check the active restraint system for correct operation. 60 Percent Seat SAFETY BELT BUCKLE AND PRETENSIONER - 60 PERCENT SEAT Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner > Page 9295 Removal WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. - All safety belt assemblies (including retractors, belt tension sensor [BTS], if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after every collision. All new belt assemblies should be installed unless a qualified technician finds the assemblies show no damage and operate correctly. Belt assemblies not in use during a collision should also be inspected and new assemblies installed if either damage or incorrect operation is noted. Failure to follow these instructions could increase the risk of injury in collisions. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Position the seat to gain access to all seat fasteners. 2. Depower the SRS. 3. Remove the 60 percent front seat. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner > Page 9296 4. NOTE: Make note of the wire harness routing for installation. Detach the electrical connectors and route out the wire harnesses. 5. Remove the nut and the safety belt buckle pretensioner assembly. Installation 1. Install the safety belt buckle and pretensioner. 1 Position the safety belt buckle and pretensioner to the seat. Align the safety belt buckle and pretensioner locator tab to the hole in the seat frame. - Check that the safety belt buckle end is accessible after positioning. 2 Install the nut. Tighten to 40 Nm (30 lb-ft). 3 Route the safety belt buckle and pretensioner usage detection switch and pretensioner electrical connectors as noted in removal. 2. Attach the electrical connectors and route the wire harnesses as noted in removal. 3. Install the 60 percent front seat. 4. Repower the SRS. 5. Check the active restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner > Page 9297 Seat Belt Tensioner: Service and Repair Safety Belt Pretensioner Disposal Deployed SAFETY BELT PRETENSIONER DISPOSAL - DEPLOYED 1. WARNING: The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. Dispose of the deployed safety belt pretensioner in the same manner as any other part to be scrapped. Inoperative SAFETY BELT PRETENSIONER DISPOSAL - UNDEPLOYED, INOPERATIVE WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Carry a live safety belt retractor pretensioner or safety belt buckle pretensioner so as to keep fingers and clothing away from moveable parts. This will reduce the risk of injury in the event of an accidental deployment. NOTE: All inoperative safety belt buckle pretensioners and safety belt retractor pretensioners have been placed on the Mandatory Return List. All damaged safety belt buckle pretensioners and safety belt retractor pretensioners must be treated the same as any inoperative live safety belt buckle pretensioner or safety belt retractor pretensioner being returned. 1. Depower the system. 2. Remove the inoperative safety belt buckle pretensioner or safety belt retractor pretensioner from the vehicle. 3. Package and return the inoperative safety belt buckle pretensioner or safety belt retractor pretensioner to Ford Motor Company. Scrapped Vehicle SAFETY BELT PRETENSIONER DISPOSAL - UNDEPLOYED, SCRAPPED VEHICLE Remote Deployment WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - 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 safety belt pretensioner is deployed, hearing protection is required. - Do not position the safety belt buckle pretensioner or safety belt retractor pretensioner so that moveable parts contact the support surface, as the forces of the deploying pretensioner can cause it to ricochet and cause personal injury. All vehicles 1. Depower the system. 2. Remove the safety belt buckle pretensioner assembly from the vehicle. Safety Belt Buckle Pretensioner Without a Hard-Wired Electrical Connector 3. Cut and remove the safety belt buckle pretensioner electrical connector from the main seat wire harness, leaving about 4 inches of extra wire. 4. Attach the electrical connector to the safety belt buckle pretensioner. All vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Safety Belt Buckle and Pretensioner > Page 9298 5. Strip the wires near the electrical connector. 6. Obtain 2 wires (20 gauge minimum) at least 6.1 meters (20 feet) long and attach one end of each wire to the safety belt buckle pretensioner wires. 7. Position the safety belt buckle pretensioner assembly on a flat surface in an open outdoor area so that moveable parts do not contact the support surface. 8. Remain at least 6.1 meters (20 feet) away from the safety belt buckle pretensioner assembly. 9. Deploy the safety belt buckle pretensioner by touching the other ends of the 2 wires to the terminals of a 12-volt battery. 10. To allow for cooling, wait at least 10 minutes before approaching the deployed safety belt buckle pretensioner. 11. Dispose of the deployed safety belt buckle pretensioner in the same manner as any other part to be scrapped. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations View 151-26 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Page 9302 C356 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Page 9303 Seat Sensor/Switch: Description and Operation SEAT TRACK POSITION SENSOR The seat track position sensor is mounted to a bracket attached to the inboard side of the seat track. The seat track position sensor informs the restraints control module (RCM) of the driver seat position. The RCM uses this information in determining the deployment rate of the dual-stage driver air bag module. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor View 151-1 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 9309 View 151-19 (Left Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 9310 View 151-21 (Right Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 9311 View 151-28 (Driver Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor > Page 9312 View 151-29 (Passenger Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Forward Crash Sensor C177 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Forward Crash Sensor > Page 9315 C539 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Forward Crash Sensor > Page 9316 C631 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Forward Crash Sensor > Page 9317 C9004 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Forward Crash Sensor > Page 9318 C9005 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Page 9319 Impact Sensor: Description and Operation SENSORS WARNING: - The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the RCM must be replaced whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. - Vehicle sensor orientation is critical for correct 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 correctly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. For these vehicles, the SRS uses up to 8 sensors. Within the RCM there can be up to 3 safing sensors which are not separately serviced. The RCM will always have at least 1 safing sensor for front impact. Two more safing sensors are used if the vehicle is equipped with safety canopy modules. The RCM is mounted to the center tunnel beneath the console or bench seat. All vehicles will have a front impact severity sensor that is located in the front-center of the vehicle, mounted near the bottom of the hood latch support bracket. If the vehicle is equipped with safety canopy modules, there are 4 additional side impact sensors external to the RCM. One front row side impact sensor is located behind each of the front door interior trim panels. One second row side impact sensor is located at the base of each C-pillar. Mounting orientation is critical for correct operation of all impact and rollover sensors. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor Impact Sensor: Service and Repair Front Impact Severity Sensor FRONT IMPACT SEVERITY SENSOR Removal and Installation WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - Front bumper removed for clarity. 1. Depower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 9322 2. NOTE: The front impact severity sensor is mounted on the bottom of the hood latch support bracket. Remove the pin-type retainers and lower the front lower splash shield to access the front impact severity sensor. 3. WARNING: The tightening torque of the air bag front impact severity sensor retaining nut is critical for correct system operation. CAUTION: If the hood latch support bracket or weld stud are damaged in any way that would affect the way the front impact severity sensor mounts to its original manufactured position, a new hood latch support bracket must be installed. NOTE: Note the position of the front impact severity sensor locator tabs to the hood latch support bracket alignment holes for installation. - Make sure the hood latch support bracket and front impact severity sensor mating surfaces are clean and debris free. Remove the front impact severity sensor nut. To install, tighten to 12 Nm (9 lb-ft) 4. Disconnect the electrical connector and remove the front impact severity sensor. 5. To install, reverse the removal procedure. 6. Repower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 9323 Impact Sensor: Service and Repair Side Impact Sensor - C-Pillar SIDE IMPACT SENSOR - C-PILLAR 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. - Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and correctly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To reduce the risk of personal injury, do not use any memory saver devices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 9324 NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. - Driver side shown, passenger side similar. 1. Depower the system. 2. Lift to release and remove the rear door scuff plate. 3. Remove the safety belt retractor anchor bolt. 4. Pull out at the front of the rear quarter trim panel, releasing the retaining clips, allowing access to the side impact sensor. 5. Remove the side impact sensor bolt. 6. Disconnect the side impact sensor electrical connector and remove the sensor and bracket. Installation 1. Make sure the second row side impact sensor tabs are aligned to the bracket. 2. Position the side impact sensor and bracket locator pin to the opening in the quarter panel sheet metal and install the bolt. - To install, tighten to 12 Nm (9 lb-ft). 3. Connect the side impact sensor electrical connector. 4. Align the rear quarter trim panel and push in, seating the retaining clips. 5. NOTE: Make sure the safety belt webbing is not twisted prior to installation. Install the safety belt retractor anchor bolt. To install, tighten to 40 Nm (30 lb-ft). - Verify the safety belt retractor operates without excessive effort or binding. 6. Install the rear door scuff plate. 7. Repower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 9325 Impact Sensor: Service and Repair Side Impact Sensor - Front Door SIDE IMPACT SENSOR - FRONT DOOR Removal and Installation WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Vehicle sensor orientation is critical for 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 reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - Driver side shown, passenger side similar. 1. Depower the system. 2. Remove the front interior door trim panel on the side with the affected side impact sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 9326 3. Separate the weathershield enough to access the side impact sensor. 4. Disconnect the side impact sensor electrical connector. 5. WARNING: The tightening torque of the side impact sensor retaining bolt is critical for correct system operation. CAUTION: The ground wire must be placed between the bolt head and the sensor. Never position the ground wire between the J-clip retaining nut and the sensor. - Always replace the J-clip retaining nut whenever installing a side impact sensor. NOTE: Make sure the side impact sensor mating surfaces are clean and free of foreign material. - Note the position of the side impact sensor locating tabs for installation. Remove the bolt and the side impact sensor. To install, tighten to 12 Nm (9 lb-ft). 6. To install, reverse the removal procedure. 7. Repower the system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger View 151-17 (RH A-Pillar) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger > Page 9331 View 151-26 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver C3065 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver > Page 9334 C3066 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Page 9335 Seat Belt Buckle Switch: Description and Operation SAFETY BELT BUCKLE SWITCHES As part of the supplemental restraint system (SRS), the driver and front outboard passenger safety belt buckles are equipped with safety belt buckle switches. The safety belt buckle switches indicate to the restraints control module (RCM) whether the safety belts are connected or disconnected. The RCM uses this information in determining the deployment rate of the dual-stage driver and passenger air bag modules. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations View 151-26 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 9339 C356 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 9340 Seat Sensor/Switch: Description and Operation SEAT TRACK POSITION SENSOR The seat track position sensor is mounted to a bracket attached to the inboard side of the seat track. The seat track position sensor informs the restraints control module (RCM) of the driver seat position. The RCM uses this information in determining the deployment rate of the dual-stage driver air bag module. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 9346 C2075 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 9347 Accessory Delay Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 9348 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Amplifier > Component Information > Locations View 151-23 (Roof) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Amplifier > Component Information > Locations > Page 9353 Antenna Amplifier: Diagrams C4194a C4194b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Service and Repair Antenna, Navigation: Service and Repair GLOBAL POSITIONING SYSTEM (GPS) ANTENNA Removal and Installation 1. Disconnect the battery. 2. Remove the audio unit. 3. Remove the passenger airbag module. 4. Remove the bolt and the GPS antenna. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Lead-In Cable - Front Antenna Cable: Service and Repair Antenna Lead-In Cable - Front ANTENNA LEAD-IN CABLE - FRONT Removal and Installation 1. Remove the audio unit. 2. Remove the RH scuff plate. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Lead-In Cable - Front > Page 9362 3. Remove the RH A-pillar lower trim panel. 4. Disconnect the rear antenna lead-in cable from the front antenna lead-in cable. 5. NOTE: The antenna is an integral part of the wiring harness and cannot be replaced separately from the harness. Cut the ends off of the old antenna cable and tape the remainder to the wiring harness to prevent noise. Remove the ground plate and remove the antenna cable ends. 6. NOTE: When installing the new cable, tape or wire-tie the new cable to the wiring harness to prevent noise. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Lead-In Cable - Front > Page 9363 Antenna Cable: Service and Repair Antenna Lead-In Cable - Rear ANTENNA LEAD-IN CABLE - REAR Removal and Installation 1. Remove the RH scuff plate. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Lead-In Cable - Front > Page 9364 2. Remove the RH A-pillar lower trim panel. 3. Disconnect the rear antenna lead-in cable from the front antenna lead-in cable. 4. Remove the RH rear door scuff plate. 5. Remove the RH rear quarter trim. 6. Lower the headliner enough to gain access to the rear antenna cable connection. 7. Disconnect the rear antenna lead-in cable from the antenna isolator module. 8. NOTE: The antenna is an integral part of the wiring harness and cannot be replaced separately from the harness. Cut the ends off of the old antenna cable and tape the remainder to the wiring harness to prevent noise. Remove the ground plate and remove the antenna cable ends. 9. NOTE: When installing the new cable, tape or wire tie the new cable to the wiring harness to prevent noise. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Diagrams C2007 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Diagrams > Page 9369 Alarm System Transponder: Service and Repair PASSIVE ANTI-THEFT SYSTEM (PATS) TRANSCEIVER Removal And Installation 1. Remove the steering wheel. 2. Remove 2 screws and the lower steering column shroud. 3. Remove the ignition lock cylinder cover. 4. Disconnect the PATS transceiver electrical connector. 5. Remove the screw and the PATS transceiver. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 (V8-5.4L VIN 5 (2006)) 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 9375 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 (V8-5.4L VIN 5 (2006)) 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 9376 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Page 9377 View 151-28 (Driver Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Page 9378 C500 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Service and Repair > Remote Keyless Entry Keypad Code Programming Keyless Entry Key-Pad: Service and Repair Remote Keyless Entry Keypad Code Programming REMOTE KEYLESS ENTRY KEYPAD CODE PROGRAMMING 1. Enter the permanent factory remote keyless entry (RKE) keypad code. 2. Press the 1/2 button within 5 seconds to activate the programming mode. Holding the 1/2 button for more than 2 seconds after activation erases the stored customer code. The doors lock, then unlock, confirming the code is erased. The existing code does not need to be erased to program a new code. 3. Within 5 seconds, enter the new 5-digit RKE keypad code. The doors lock and unlock to confirm the new code is programmed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Service and Repair > Remote Keyless Entry Keypad Code Programming > Page 9381 Keyless Entry Key-Pad: Service and Repair Autolock and Horn Chirp Programming AUTOLOCK AND HORN CHIRP PROGRAMMING 1. Close all the doors. 2. Confirm that the ignition switch is in the OFF position. 3. Turn the ignition switch from OFF to RUN. 4. NOTE: Steps 4 through 8 must be carried out within 30 seconds. Press the power door lock UNLOCK button 3 times. 5. Turn the ignition switch from RUN to OFF. 6. Press the power door lock UNLOCK button 3 times. 7. Turn the ignition switch from OFF to RUN. 8. Verify the horn chirps. This indicates the system is in the enable/disable mode is ready to accept program changes. 9. Press the power door lock UNLOCK button 1 time to toggle the autolock/relock feature OFF. 10. Press the power door lock LOCK button once to enter the command. 11. Verify the horn chirps 1 time. There should only be 1 chirp indicating that autolock/relock feature is disabled. If 1 chirp is heard, followed by a longer sound of the horn, the autolock/relock feature has just been enabled. Return to Step 9. 12. Turn the ignition switch to the OFF position to exit the enable/disable mode. 13. Exit the vehicle and verify the horn chirps once to indicate that a feature has been changed and that autolock/relock is disabled. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Service and Repair > Remote Keyless Entry Keypad Code Programming > Page 9382 Keyless Entry Key-Pad: Service and Repair Remote Keyless Entry Keypad REMOTE KEYLESS ENTRY KEYPAD Removal and Installation 1. Remove the exterior mirror. 2. Disconnect the RKE keypad electrical connector. 3. Remove the front door window glass. 4. CAUTION: Damage to the base moulding may occur during the removal procedure. Remove the front door window base moulding. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Service and Repair > Remote Keyless Entry Keypad Code Programming > Page 9383 5. Remove the RKE keypad. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 REMOTE KEYLESS ENTRY TRANSMITTER PROGRAMMING NOTE: - All remote keyless entry (RKE) transmitters must be programmed at the same time. - Programming (or reprogramming) of the RKE transmitters can be accomplished using a diagnostic tool or by carrying out the following steps: 1. The vehicle must be electronically unlocked before entering program mode using the door lock control switch while the driver door is open. 2. Turn the ignition switch from the OFF to the RUN position 8 times within 10 seconds, with the eighth turn ending in RUN. If the module successfully enters program mode, it locks and then unlocks all the doors. 3. Within 20 seconds, press any button on an RKE transmitter, and the doors lock and then unlock to confirm that each RKE transmitter is programmed. Repeat this step for each RKE transmitter. 4. If the door locks do not respond for any RKE transmitter, wait several seconds and press the button again. If the door locks still fail to respond, refer to Inspection and Verification. (Make sure that no more than the maximum number of RKE transmitters are attempted to be programmed.) See: Body and Frame/Locks/Power Locks/Testing and Inspection/Initial Inspection and Diagnostic Overview/Inspection and Verification 5. Exiting the programming mode is accomplished if one of the following occurs: - The key transitions to the OFF position. - 20 seconds have passed since entering programming mode or since the last RKE transmitter was programmed. - The maximum number (6) of RKE transmitters have been programmed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Control Module: > 06-20-5 > Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743 Parking Assist Control Module: Customer Interest Parking Assist System - Speaker Inop./DTC C1742/C1743 TSB 06-20-5 10/16/06 PARKING AID SPEAKER INOPERATIVE - DTCS C1742 AND C1743 FORD: 2005-2007 Five Hundred, Freestyle 2004-2006 Escape, Expedition, Explorer, F-150 2004-2007 F-250, F-350 MERCURY: 2005-2007 Montego 2004-2006 Mountaineer 2005-2006 Mariner ISSUE Some 2004-2007 vehicles equipped with the parking aid reverse sensing system (RSS) may experience low or no audible sound due to speaker issues related to the RSS. The speaker is attached to the module which may exhibit diagnostic trouble codes (DTCs) C1742 (Rear Sounder Circuit Fault) and/or C1743 (Rear Sounder Short). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Verify that DTCs C1742 and/or C1743 are present. Also, low audible or intermittent audible warning condition may exist as well. 2. If DTCs C1742 and/or C1743 are present, replace parking aid speaker on module with speaker in Speaker Kit. Follow instructions in Speaker Kit. 3. Clear DTCs and repeat check for DTCs C1742 and/or C1743. 4. If DTCs C1742 and/or C1743 go away and speaker sounds, the repair is complete. 5. If DTCs remain, follow normal diagnostics in the appropriate Workshop Manual, Section 413-13 Pinpoint Test F. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 062005A 2004-2006 Expedition: 1.2 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2007 Super Duty 0.6 Hr. 250/350: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Control Module: > 06-20-5 > Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743 > Page 9396 062005A 2004-2005 1.1 Hrs. Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2006 Explorer/Mountaineer: 1.3 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 F-150: Replace 0.5 Hr. Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 Escape, 0.8 Hr. 2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Five 1.3 Hrs. Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Freestyle: 0.7 Hr. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR 31012AL, 31012AT) DEALER CODING CONDITION BASIC PART NO. CODE 15K864 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Control Module: > 06-20-5 > Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743 Parking Assist Control Module: All Technical Service Bulletins Parking Assist System - Speaker Inop./DTC C1742/C1743 TSB 06-20-5 10/16/06 PARKING AID SPEAKER INOPERATIVE - DTCS C1742 AND C1743 FORD: 2005-2007 Five Hundred, Freestyle 2004-2006 Escape, Expedition, Explorer, F-150 2004-2007 F-250, F-350 MERCURY: 2005-2007 Montego 2004-2006 Mountaineer 2005-2006 Mariner ISSUE Some 2004-2007 vehicles equipped with the parking aid reverse sensing system (RSS) may experience low or no audible sound due to speaker issues related to the RSS. The speaker is attached to the module which may exhibit diagnostic trouble codes (DTCs) C1742 (Rear Sounder Circuit Fault) and/or C1743 (Rear Sounder Short). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Verify that DTCs C1742 and/or C1743 are present. Also, low audible or intermittent audible warning condition may exist as well. 2. If DTCs C1742 and/or C1743 are present, replace parking aid speaker on module with speaker in Speaker Kit. Follow instructions in Speaker Kit. 3. Clear DTCs and repeat check for DTCs C1742 and/or C1743. 4. If DTCs C1742 and/or C1743 go away and speaker sounds, the repair is complete. 5. If DTCs remain, follow normal diagnostics in the appropriate Workshop Manual, Section 413-13 Pinpoint Test F. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 062005A 2004-2006 Expedition: 1.2 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2007 Super Duty 0.6 Hr. 250/350: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Control Module: > 06-20-5 > Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743 > Page 9402 062005A 2004-2005 1.1 Hrs. Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2006 Explorer/Mountaineer: 1.3 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 F-150: Replace 0.5 Hr. Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 Escape, 0.8 Hr. 2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Five 1.3 Hrs. Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Freestyle: 0.7 Hr. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR 31012AL, 31012AT) DEALER CODING CONDITION BASIC PART NO. CODE 15K864 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Technical Service Bulletins > Page 9403 View 151-19 (Left Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Technical Service Bulletins > Page 9404 Parking Assist Control Module: Diagrams C4014a C4014b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Technical Service Bulletins > Page 9405 C4226 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Technical Service Bulletins > Page 9406 Parking Assist Control Module: Service and Repair PARKING AID MODULE Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Technical Service Bulletins > Page 9407 Removal and Installation 1. Remove the LH quarter trim panel. 2. Remove the parking aid module. 1 Disconnect the electrical connector(s). 2 Remove the parking aid module screw. 3 Remove the parking aid module. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Inner/Outer Left View 151-19 (Left Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Inner/Outer Left > Page 9412 View 151-21 (Right Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Inner/Outer Left > Page 9413 View 151-21 (Right Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Radar Sensor C4191 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Radar Sensor > Page 9416 Parking Assist Distance Sensor: Diagrams Parking Aid Ultrasonic Sensor C4192 C4193 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Radar Sensor > Page 9417 C4009 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Radar Sensor > Page 9418 C4011 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Radar Sensor > Page 9419 Parking Assist Distance Sensor: Diagrams C4191 C4192 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Radar Sensor > Page 9420 C4193 C4009 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Radar Sensor > Page 9421 C4011 C4010 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Radar Sensor > Page 9422 C4012 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Page 9423 Parking Assist Distance Sensor: Service and Repair PARKING AID SENSOR Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Page 9424 Removal and Installation All vehicles 1. Remove the rear bumper cover. 2. Remove the nuts and the foam absorber from the bumper cover. 3. Remove the ultrasonic sensor(s). 1 Disconnect the electrical connector(s). 2 Release the locking tabs. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Page 9425 3 Remove the ultrasonic sensor(s). Navigator 4. Remove the radar sensor. 1 Disconnect the electrical connector. 2 Remove the two parking aid radar sensor nuts. 3 Remove the radar sensor. All vehicles 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Warning Indicator: > 06-20-5 > Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743 Parking Assist Warning Indicator: Customer Interest Parking Assist System - Speaker Inop./DTC C1742/C1743 TSB 06-20-5 10/16/06 PARKING AID SPEAKER INOPERATIVE - DTCS C1742 AND C1743 FORD: 2005-2007 Five Hundred, Freestyle 2004-2006 Escape, Expedition, Explorer, F-150 2004-2007 F-250, F-350 MERCURY: 2005-2007 Montego 2004-2006 Mountaineer 2005-2006 Mariner ISSUE Some 2004-2007 vehicles equipped with the parking aid reverse sensing system (RSS) may experience low or no audible sound due to speaker issues related to the RSS. The speaker is attached to the module which may exhibit diagnostic trouble codes (DTCs) C1742 (Rear Sounder Circuit Fault) and/or C1743 (Rear Sounder Short). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Verify that DTCs C1742 and/or C1743 are present. Also, low audible or intermittent audible warning condition may exist as well. 2. If DTCs C1742 and/or C1743 are present, replace parking aid speaker on module with speaker in Speaker Kit. Follow instructions in Speaker Kit. 3. Clear DTCs and repeat check for DTCs C1742 and/or C1743. 4. If DTCs C1742 and/or C1743 go away and speaker sounds, the repair is complete. 5. If DTCs remain, follow normal diagnostics in the appropriate Workshop Manual, Section 413-13 Pinpoint Test F. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 062005A 2004-2006 Expedition: 1.2 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2007 Super Duty 0.6 Hr. 250/350: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Warning Indicator: > 06-20-5 > Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743 > Page 9434 062005A 2004-2005 1.1 Hrs. Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2006 Explorer/Mountaineer: 1.3 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 F-150: Replace 0.5 Hr. Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 Escape, 0.8 Hr. 2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Five 1.3 Hrs. Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Freestyle: 0.7 Hr. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR 31012AL, 31012AT) DEALER CODING CONDITION BASIC PART NO. CODE 15K864 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Warning Indicator: > 06-20-5 > Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743 Parking Assist Warning Indicator: All Technical Service Bulletins Parking Assist System - Speaker Inop./DTC C1742/C1743 TSB 06-20-5 10/16/06 PARKING AID SPEAKER INOPERATIVE - DTCS C1742 AND C1743 FORD: 2005-2007 Five Hundred, Freestyle 2004-2006 Escape, Expedition, Explorer, F-150 2004-2007 F-250, F-350 MERCURY: 2005-2007 Montego 2004-2006 Mountaineer 2005-2006 Mariner ISSUE Some 2004-2007 vehicles equipped with the parking aid reverse sensing system (RSS) may experience low or no audible sound due to speaker issues related to the RSS. The speaker is attached to the module which may exhibit diagnostic trouble codes (DTCs) C1742 (Rear Sounder Circuit Fault) and/or C1743 (Rear Sounder Short). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Verify that DTCs C1742 and/or C1743 are present. Also, low audible or intermittent audible warning condition may exist as well. 2. If DTCs C1742 and/or C1743 are present, replace parking aid speaker on module with speaker in Speaker Kit. Follow instructions in Speaker Kit. 3. Clear DTCs and repeat check for DTCs C1742 and/or C1743. 4. If DTCs C1742 and/or C1743 go away and speaker sounds, the repair is complete. 5. If DTCs remain, follow normal diagnostics in the appropriate Workshop Manual, Section 413-13 Pinpoint Test F. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 062005A 2004-2006 Expedition: 1.2 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2007 Super Duty 0.6 Hr. 250/350: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Warning Indicator: > 06-20-5 > Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743 > Page 9440 062005A 2004-2005 1.1 Hrs. Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2006 Explorer/Mountaineer: 1.3 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 F-150: Replace 0.5 Hr. Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 Escape, 0.8 Hr. 2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Five 1.3 Hrs. Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Freestyle: 0.7 Hr. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR 31012AL, 31012AT) DEALER CODING CONDITION BASIC PART NO. CODE 15K864 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Warning Indicator > Component Information > Technical Service Bulletins > Page 9441 C4015 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Locations View 151-12 (Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Locations > Page 9445 C253 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Locations > Page 9446 Driver/Vehicle Information Display: Description and Operation INFORMATION AND MESSAGE CENTER The message center display is a green vacuum fluorescent, fixed format display. The message center is a 2-line display integrated into the center of the instrument cluster and is controlled by the message center switches. Refer to the Owner's Literature for operating instructions. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 Principles of Operation PRINCIPLES OF OPERATION The message center is a vacuum fluorescent display, part of the instrument cluster. The message center electronic functions use both hardwired, and controller area network (CAN) circuitry to transmit and receive information. As a technician, it is very important to understand: - where the input (command) originates. - all the information (messages) necessary in order for a feature to operate. - which module(s) receive(s) the input or command message. - if the module that received the input (message) controls the output of the feature, or if it outputs a message over the CAN to another module. - which module controls the output of the feature. The message center provides the following features: - information displays - setup displays - warning messages - system check messages The message center information can be selected through a set of 3 buttons: - INFO - SETUP - RESET Information Displays The information displays are non-timed modes. The selected mode remains on until the driver presses a message center button to change the mode or it is overridden by another mode. The information display modes are: odometer - trip odometer - compass - distance to empty (DTE) - average fuel economy Setup Displays The setup displays are timed modes and terminate after a finite interval. The setup display modes are: system check - English/metric units - power liftgate on/off (if equipped) - running board auto in/out (if equipped) - easy exit seat (if equipped) - autolamp delay - language Warning Messages The warning messages are single cycle, non-resettable and repetitive warning messages. The single cycle warning messages are: CHECK SUSPENSION - CHECK COMPASS MODULE - NO RESPONSE COMPASS - ENGINE TEMP DATA - COMPASS DATA ERROR - DOOR SENSOR DATA ERROR - CHARGING SYSTEM DATA ERROR - CHECK PARK ASSIST - CHECK FUEL CAP - LOW WASHER FLUID LEVEL The single cycle warning messages display once whenever the ignition switch is turned to ON or a fault occurs in a system and can be cleared by pressing the RESET button. The repetitive warning messages are: LOW BRAKE FLUID LEVEL - CHECK CHARGING SYSTEM - LOW FUEL LEVEL - LOW OIL PRESSURE Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9449 - CHECK ENGINE TEMPERATURE - TEMPORARY 4x4 HIGH - CHECK ADV/TRAC - CHECK TIRE PRESSURE The repetitive warning messages are displayed at a fixed interval whenever the ignition switch is turned ON or is in the ACC position. To remove a repetitive warning message, press the RESET button. The message only reoccurs after 10 minutes or until the warning condition is corrected. The non-resettable warning messages are: DOOR AJAR - STOP ENGINE SAFELY - REDUCED ENGINE POWER - ENGINE FAILSAFE MODE - PARK ASSIST ON/OFF - TRAIN LF TIRE - TRAIN LR TIRE - TRAIN RF TIRE - TRAIN RR TIRE - TRAIN SPARE TIRE - TIRE TRAINING MODE COMPLETE - TIRES NOT TRAINED - PARK BRAKE ENGAGED The non-resettable warning messages display whenever the ignition switch is turned to ON and a fault occurs in a system. The fault must be corrected to clear the non-resettable warning messages. Inspection and Verification INSPECTION AND VERIFICATION 1. Verify the customer concern. Visual Inspection Chart 2. Visually inspect for obvious signs of mechanical or electrical damage. 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the cause is not visually evident, connect the diagnostic tool to the data link connector and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool 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. 5. If the diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool operating manual. 6. Carry out the diagnostic tool data link test. If the diagnostic tool responds with: - ISO, SCP or CAN circuit fault; all electronic control units no response/not equipped, refer to Information Bus (Module Communications Network). - No response/not equipped for the instrument cluster, refer to Instrument Cluster. - System passed, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs, and carry out self-test diagnostics for the instrument cluster. 7. If the DTCs retrieved are related to the concern, refer to the Instrument Cluster Diagnostic Trouble Code (DTC) Index. See: Diagnostic Trouble Code Descriptions 8. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9450 B1209-U2013 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9451 Driver/Vehicle Information Display: Symptom Related Diagnostic Procedures Symptom Chart (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9452 Symptom Chart (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9453 Symptom Chart (Part 3) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9454 Symptom Chart (Part 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9455 Symptom Chart (Part 5) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9456 Driver/Vehicle Information Display: Pinpoint Tests Test A: The Message Center Is Not Operating Correctly PINPOINT TEST A: THE MESSAGE CENTER IS NOT OPERATING CORRECTLY A1 Normal Operation The message center functionality is controlled through the message center switches, which are hardwired to the instrument cluster through circuit 1396 (VT/WH) and circuit 1411 (GY/OG). Each message center switch uses a different resistance value allowing the instrument cluster to determine which switch is pressed. Possible Causes - message center switches - instrument cluster Test B: The Compass Is Inoperative PINPOINT TEST B: THE COMPASS IS INOPERATIVE Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9457 B1-B3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9458 B3 Continued Normal Operation The compass sensor module receives voltage from central junction box (CJB) fuse 27 (5A) through circuit 1003 (GY/YE) and is grounded through circuit 875 (BK/LB). The compass sensor module communicates the vehicle direction to the instrument cluster, and the direction is displayed in the message center. The compass sensor module uses circuit 702 (WH/BK) and circuit 703 (WH/OG) to communicate to the instrument cluster. Possible Causes - fuse - circuit 702 (WH/BK) open or short to ground - circuit 703 (WH/OG) open or short to ground - circuit 875 (BK/LB) open - circuit 1003 (GY/YE) open - compass sensor module Test C: The Compass Is Inaccurate PINPOINT TEST C: THE COMPASS IS INACCURATE Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9459 C1-C3 Normal Operation The compass sensor module communicates the vehicle direction to the instrument cluster to display in the message center. Possible Causes - compass sensor module - vehicle magnetization - zone setting - calibration Test D: The Message Center Switch Does Not Operate Correctly PINPOINT TEST D: THE MESSAGE CENTER SWITCH DOES NOT OPERATE CORRECTLY Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9460 D1-D3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9461 D4-D5 Normal Operation The message center switch assembly uses circuits 1396 (VT/WH) and 1411 (GY/OG) to communicate the requested switch function to the message center. Possible Causes - circuit 1396 (VT/WH) open or short to ground - circuit 1411 (GY/OG) open or short to ground - message center switch - instrument cluster Test E: The Power Liftgate Display Is Inoperative PINPOINT TEST E: THE POWER LIFTGATE DISPLAY IS INOPERATIVE E1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9462 E2-E3 Normal Operation The vehicle security module (VSM) sends a voltage reference signal through circuit 700 (WH/VT) to the power liftgate module. When the reference signal loses the ground signal by the opening of the power liftgate, the VSM sends a signal over the communication network to the instrument cluster, illuminating the power liftgate display. Possible Causes - instrument cluster - power liftgate Test F: The Power Running Boards Display Is Inoperative PINPOINT TEST F: THE POWER RUNNING BOARDS DISPLAY IS INOPERATIVE F1-F3 Normal Operation The instrument cluster receives the running board status from the power liftgate module over the communication network. The retractable running boards are controlled by the power liftgate module over the control circuits 1944 (BN/PK) (left side), and 1945 (VT/WH) (right side). The running board motors are grounded through circuit 57 (BK). The retractable running board motors receive a ground signal from the power liftgate module to deploy and an open signal to retract. Possible Causes - instrument cluster - power running boards Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9463 Test G: The Park Assist On/Off Display Is Inoperative PINPOINT TEST G: THE PARK ASSIST ON/OFF DISPLAY IS INOPERATIVE G1-G3 Normal Operation The parking aid system is enabled when the ignition switch is in the RUN position and REVERSE is selected. The system can be disabled through the message center RESET switch located in the instrument cluster. The parking aid menu is displayed until the transmission is taken out of REVERSE. While the menu is displayed, pressing the message center RESET switch changes the parking aid system status to OFF. The parking aid system is disabled if a fault is detected in 1 of the 4 sensors, the parking aid speaker, or the parking aid module. This is indicated by the parking aid disabled warning CHECK BACKUP AID displayed in the message center. The parking aid module communicates with the instrument cluster through the communication network. Possible Causes - instrument cluster - parking aid system Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Page 9464 Driver/Vehicle Information Display: Service and Repair MESSAGE CENTER SWITCH Removal and Installation 1. Remove the instrument cluster finish panel. 2. NOTE: Navigator is shown, Expedition is similar. Press the tabs and remove the message center switch. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Page 9465 Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Diagrams C9020 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Diagrams > Page 9470 DVD Player: Service and Repair DIGITAL VERSATILE DISC (DVD) PLAYER Removal and Installation CAUTION: When removing the DVD player do not pull on the display. This may cause damage to the unit and void the warranty. 1. Open the video display door. 2. Remove the 4 DVD player screws. 3. NOTE: The DVD player must be supported while disengaging the clips. Disengage the 3 retaining clips and remove the DVD player. Disconnect the electrical connector. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Description and Operation Garage Door Opener Transmitter: Description and Operation UNIVERSAL TRANSMITTER The HomeLink(R) universal transmitter provides a convenient way to substitute up to 3 hand-held transmitters with a single built-in device. The universal transmitter: - will operate garage doors, gates and home/office lighting and security systems. - will actually learn and transmit the radio frequency of up to 3 hand-held transmitters from any of the systems mentioned above. - is an integral part of the left sun visor assembly and is powered by the vehicle battery and charging system. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Garage Door Opener Transmitter: Initial Inspection and Diagnostic Overview INSPECTION AND VERIFICATION 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical damage. VISUAL INSPECTION CHART Mechanical Damaged universal transmitter - Damaged receiver 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the fault is not visually evident, verify the symptom and refer to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9476 Symptom Chart Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9477 Garage Door Opener Transmitter: Pinpoint Tests PINPOINT TEST A: THE UNIVERSAL TRANSMITTER IS INOPERATIVE A1-A2 Normal Operation The universal transmitter receives voltage on circuit 705 (LG/OG) and ground on circuit 57 (BK). Possible Causes - circuit 705 (LG/OG) open or short to ground - circuit 57 (BK) open - universal transmitter Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Page 9478 Garage Door Opener Transmitter: Service and Repair UNIVERSAL TRANSMITTER PROGRAMMING WARNING: A garage door opening system that cannot stop or reverse itself after detecting an object in its path does not meet current federal safety standards. To decrease the risk of serious injury or death, do not use this HomeLink(R) transmitter with a door opening system that lacks stop and reverse features as required by federal standards. This includes any garage door opening system manufactured before April 1, 1982. For more information, call HomeLink(R) customer assistance at 1-800-355-3515. 1. CAUTION: During this procedure, the system that you are programming will be made to operate. Make sure that people or objects are clear of the garage door or gate being programmed. Verify the hand-held transmitter is operative. 2. Prepare for programming the universal transmitter by erasing all three channels by holding down the two outside buttons until the red light begins to flash (20-30 seconds). Release both buttons. 3. Select one of the three universal transmitter channels to be programmed by pressing the desired button. 4. Hold the end of the hand-held transmitter 25-51mm (1-2 in) from the front surface of the universal transmitter so that the red light can still be seen. 5. NOTE: During programming, the hand-held transmitter may automatically stop transmitting after two seconds, which may not be long enough to program the universal transmitter. If programming this type of hand-held transmitter, continue to hold the button on the universal transmitter while re-pressing the hand-held transmitter button every two seconds (Canada only). Use both hands to press the hand-held transmitter button and the desired button on the universal transmitter. Do not release either button. 6. Hold down both buttons until the red light on the universal transmitter flashes, first slowly and then rapidly. Release both buttons when the rapid flashing begins. The universal transmitter has successfully learned the new frequency signal and can be used in place of the hand-held transmitter(s). 7. NOTE: If the hand-held transmitter appears to program the universal transmitter but does not open the garage door, the garage door opener may have a "code protected" or "rolling code" feature. To operate, simply press the appropriate button on the universal transmitter. The red light is on while the signal is being transmitted. Training a Garage Door Opener Equipped With "Rolling Codes" 1. Program the hand-held transmitter to the universal transmitter. 2. Train the garage door opener receiver to recognize the universal transmitter. 1 Remove the cover panel from the garage door opener receiver. 2 Locate the training button on the garage door opener receiver. Location and color of the button may vary by garage door opener manufacturer. Refer to the garage door opener instruction manual or call HomeLink(R) customer assistance at 1-800-355-3515. 3 Press the training button on the garage door opener receiver for 1-2 seconds. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Page 9479 4 Press the programmed universal transmitter button for as long as the universal transmitter red light flashes (1-2 seconds). Release the button and re-press the button to confirm that the universal transmitter is trained to the receiver. 5 The garage door opener should recognize the universal transmitter. Erasing Channels 1. NOTE: Individual channels cannot be erased, but can be reprogrammed using the procedures for programming. To erase all three programmed channels, hold down the two outside buttons until the red light begins to flash (20-30 seconds). Release both buttons. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations View 151-26 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 9484 Memory Positioning Module: Diagrams C341a C341b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 9485 C341c C341d Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations View 151-28 (Driver Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 9489 C503 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 9490 Seat Memory Switch: Testing and Inspection SWITCH - MEMORY SET Memory Set Switch Remove the memory set switch. Measure the resistance between the indicated terminals while pressing the requested switches. The resistance should be less than 5 ohms for each switch position. If the resistance is not less than 5 ohms for each switch, install a new switch; otherwise, return to the calling pinpoint test. NOTE: Refer to multimeter user's manual for testing diodes. To check the memory set switch LED, connect the positive meter lead to terminal 7 and the negative lead to terminal 1. 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, install a new switch; otherwise, return to the calling pinpoint test. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Locations View 151-12 (Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Diagrams > Audio/Navigation Control Unit Navigation Module: Diagrams Audio/Navigation Control Unit C2123a C2123b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Diagrams > Audio/Navigation Control Unit > Page 9497 C2123c C2123d Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Diagrams > Audio/Navigation Control Unit > Page 9498 C2123e C2123f Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Diagrams > Audio/Navigation Control Unit > Page 9499 C2123g C2253a Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Diagrams > Audio/Navigation Control Unit > Page 9500 C2253b C2253c Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Diagrams > Audio/Navigation Control Unit > Page 9501 C2253d C2253e Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Diagrams > Audio/Navigation Control Unit > Page 9502 Navigation Module: Diagrams Navigation Module C2279a C2279b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Diagrams > Page 9503 Navigation Module: Service and Repair NAVIGATION MODULE Removal and Installation 1. Disconnect the battery. 2. Remove the lower LH and RH front floor console panels. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Diagrams > Page 9504 3. Disconnect the electrical connectors. 4. Remove the navigation module. 1 Remove the 2 navigation module rear screws. 2 Remove the 2 navigation module lateral screws. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations View 151-12 (Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations > Page 9509 C2003 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Sensor > Component Information > Diagrams C2090 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations View 151-12 (Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations > Page 9516 Pedal Positioning Switch: Diagrams C2089 C2235 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations > Page 9517 Pedal Positioning Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations > Page 9518 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations > Page 9519 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Subwoofer Amplifier C466 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Subwoofer Amplifier > Page 9525 Amplifier: Diagrams Radio Amplifier C2291a C2291b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Service and Repair > Subwoofer Amplifier Amplifier: Service and Repair Subwoofer Amplifier SUBWOOFER AMPLIFIER Removal and Installation 1. Disconnect the battery. 2. Remove the LH rear quarter trim panel. 3. Remove the 4 screws and the subwoofer amplifier. - Disconnect the electrical connector. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Service and Repair > Subwoofer Amplifier > Page 9528 Amplifier: Service and Repair Audio Amplifier AUDIO AMPLIFIER Removal and Installation 1. Disconnect the battery. 2. Remove the LH and RH floor console side finish panels. 3. Remove the 2 bolts and the audio amplifier/navigation DVD assembly. - Disconnect the electrical connectors. 4. Remove the 4 bolts and the audio amplifier. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams C3028 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Page 9533 CD Changer: Service and Repair COMPACT DISC (CD) CHANGER Removal and Installation 1. Remove the mat from the bottom of the center console storage compartment. 2. NOTE: When removing the assembly, pull the front edge of the CD changer carrier back and lift the assembly out. Remove the 4 screws and the CD changer and carrier as an assembly. Disconnect the electrical connector. 3. NOTE: Only carry out this step if installing a new CD changer. Remove the 8 screws and the CD changer from the carrier. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Radio Radio/Stereo: Diagrams Radio C240a C240b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Radio > Page 9538 C240c C240d Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Radio > Page 9539 C388 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Diagrams Remote Control: Diagrams C349a C349b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Diagrams > Page 9543 Remote Control: Service and Repair REAR AUXILIARY AUDIO CONTROLS Removal and Installation NOTE: Expedition shown, Navigator similar. 1. Remove the 2 screws under the armrest cover. 2. Remove the bolt and the center console rear trim panel. - Disengage the 2 pin-type retainers. - Disconnect the rear auxiliary audio controls electrical connector. 3. Remove the rear auxiliary audio controls unit. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Diagrams > Page 9544 - Remove the 4 screws. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Tweeter, Left Front C513 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Tweeter, Left Front > Page 9549 C613 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Tweeter, Left Front > Page 9550 C4212 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Tweeter, Left Front > Page 9551 C523 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Tweeter, Left Front > Page 9552 Speaker: Diagrams C513 C613 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Tweeter, Left Front > Page 9553 C4212 C523 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Tweeter, Left Front > Page 9554 C612 C702 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Tweeter, Left Front > Page 9555 C802 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 9556 Speaker: Description and Operation SPEAKERS The speaker system consists of the following components: - Subwoofer - Speakers On all vehicles: - The rear speakers are located behind the rear door trim panels. - The front speakers are located behind the front door trim panels. - The subwoofer is located behind the LH quarter trim panel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Subwoofer Speaker Speaker: Service and Repair Subwoofer Speaker SUBWOOFER SPEAKER Removal and Installation 1. Remove the LH quarter trim panel. 2. Remove the 3 bolts and the subwoofer speaker. - Disconnect the electrical connector. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Subwoofer Speaker > Page 9559 Speaker: Service and Repair Door Speaker DOOR SPEAKER Removal and Installation All speakers 1. Remove the door trim panels. Front door tweeter speaker 2. Remove the 2 screws and the door tweeter speaker. - Disconnect the electrical connector. Front or rear door speaker Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Subwoofer Speaker > Page 9560 3. Remove the 4 screws and the speaker. - Disconnect the electrical connector. All speakers 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 9566 C2075 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 9567 Accessory Delay Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 9568 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Locations View 151-12 (Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Diagrams > Audio/Navigation Control Unit Navigation Module: Diagrams Audio/Navigation Control Unit C2123a C2123b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Diagrams > Audio/Navigation Control Unit > Page 9574 C2123c C2123d Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Diagrams > Audio/Navigation Control Unit > Page 9575 C2123e C2123f Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Diagrams > Audio/Navigation Control Unit > Page 9576 C2123g C2253a Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Diagrams > Audio/Navigation Control Unit > Page 9577 C2253b C2253c Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Diagrams > Audio/Navigation Control Unit > Page 9578 C2253d C2253e Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Diagrams > Audio/Navigation Control Unit > Page 9579 Navigation Module: Diagrams Navigation Module C2279a C2279b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Diagrams > Page 9580 Navigation Module: Service and Repair NAVIGATION MODULE Removal and Installation 1. Disconnect the battery. 2. Remove the lower LH and RH front floor console panels. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Diagrams > Page 9581 3. Disconnect the electrical connectors. 4. Remove the navigation module. 1 Remove the 2 navigation module rear screws. 2 Remove the 2 navigation module lateral screws. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Control Module: > 06-20-5 > Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743 Parking Assist Control Module: Customer Interest Parking Assist System - Speaker Inop./DTC C1742/C1743 TSB 06-20-5 10/16/06 PARKING AID SPEAKER INOPERATIVE - DTCS C1742 AND C1743 FORD: 2005-2007 Five Hundred, Freestyle 2004-2006 Escape, Expedition, Explorer, F-150 2004-2007 F-250, F-350 MERCURY: 2005-2007 Montego 2004-2006 Mountaineer 2005-2006 Mariner ISSUE Some 2004-2007 vehicles equipped with the parking aid reverse sensing system (RSS) may experience low or no audible sound due to speaker issues related to the RSS. The speaker is attached to the module which may exhibit diagnostic trouble codes (DTCs) C1742 (Rear Sounder Circuit Fault) and/or C1743 (Rear Sounder Short). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Verify that DTCs C1742 and/or C1743 are present. Also, low audible or intermittent audible warning condition may exist as well. 2. If DTCs C1742 and/or C1743 are present, replace parking aid speaker on module with speaker in Speaker Kit. Follow instructions in Speaker Kit. 3. Clear DTCs and repeat check for DTCs C1742 and/or C1743. 4. If DTCs C1742 and/or C1743 go away and speaker sounds, the repair is complete. 5. If DTCs remain, follow normal diagnostics in the appropriate Workshop Manual, Section 413-13 Pinpoint Test F. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 062005A 2004-2006 Expedition: 1.2 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2007 Super Duty 0.6 Hr. 250/350: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Control Module: > 06-20-5 > Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743 > Page 9590 062005A 2004-2005 1.1 Hrs. Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2006 Explorer/Mountaineer: 1.3 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 F-150: Replace 0.5 Hr. Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 Escape, 0.8 Hr. 2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Five 1.3 Hrs. Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Freestyle: 0.7 Hr. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR 31012AL, 31012AT) DEALER CODING CONDITION BASIC PART NO. CODE 15K864 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Control Module: > 06-20-5 > Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743 Parking Assist Control Module: All Technical Service Bulletins Parking Assist System - Speaker Inop./DTC C1742/C1743 TSB 06-20-5 10/16/06 PARKING AID SPEAKER INOPERATIVE - DTCS C1742 AND C1743 FORD: 2005-2007 Five Hundred, Freestyle 2004-2006 Escape, Expedition, Explorer, F-150 2004-2007 F-250, F-350 MERCURY: 2005-2007 Montego 2004-2006 Mountaineer 2005-2006 Mariner ISSUE Some 2004-2007 vehicles equipped with the parking aid reverse sensing system (RSS) may experience low or no audible sound due to speaker issues related to the RSS. The speaker is attached to the module which may exhibit diagnostic trouble codes (DTCs) C1742 (Rear Sounder Circuit Fault) and/or C1743 (Rear Sounder Short). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Verify that DTCs C1742 and/or C1743 are present. Also, low audible or intermittent audible warning condition may exist as well. 2. If DTCs C1742 and/or C1743 are present, replace parking aid speaker on module with speaker in Speaker Kit. Follow instructions in Speaker Kit. 3. Clear DTCs and repeat check for DTCs C1742 and/or C1743. 4. If DTCs C1742 and/or C1743 go away and speaker sounds, the repair is complete. 5. If DTCs remain, follow normal diagnostics in the appropriate Workshop Manual, Section 413-13 Pinpoint Test F. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 062005A 2004-2006 Expedition: 1.2 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2007 Super Duty 0.6 Hr. 250/350: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Control Module: > 06-20-5 > Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743 > Page 9596 062005A 2004-2005 1.1 Hrs. Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2006 Explorer/Mountaineer: 1.3 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 F-150: Replace 0.5 Hr. Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 Escape, 0.8 Hr. 2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Five 1.3 Hrs. Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Freestyle: 0.7 Hr. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR 31012AL, 31012AT) DEALER CODING CONDITION BASIC PART NO. CODE 15K864 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > Page 9597 View 151-19 (Left Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > Page 9598 Parking Assist Control Module: Diagrams C4014a C4014b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > Page 9599 C4226 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > Page 9600 Parking Assist Control Module: Service and Repair PARKING AID MODULE Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Technical Service Bulletins > Page 9601 Removal and Installation 1. Remove the LH quarter trim panel. 2. Remove the parking aid module. 1 Disconnect the electrical connector(s). 2 Remove the parking aid module screw. 3 Remove the parking aid module. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Inner/Outer Left View 151-19 (Left Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Inner/Outer Left > Page 9607 View 151-21 (Right Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Inner/Outer Left > Page 9608 View 151-21 (Right Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Radar Sensor C4191 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Radar Sensor > Page 9611 Parking Assist Distance Sensor: Diagrams Parking Aid Ultrasonic Sensor C4192 C4193 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Radar Sensor > Page 9612 C4009 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Radar Sensor > Page 9613 C4011 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Radar Sensor > Page 9614 Parking Assist Distance Sensor: Diagrams C4191 C4192 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Radar Sensor > Page 9615 C4193 C4009 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Radar Sensor > Page 9616 C4011 C4010 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Radar Sensor > Page 9617 C4012 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 9618 Parking Assist Distance Sensor: Service and Repair PARKING AID SENSOR Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 9619 Removal and Installation All vehicles 1. Remove the rear bumper cover. 2. Remove the nuts and the foam absorber from the bumper cover. 3. Remove the ultrasonic sensor(s). 1 Disconnect the electrical connector(s). 2 Release the locking tabs. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 9620 3 Remove the ultrasonic sensor(s). Navigator 4. Remove the radar sensor. 1 Disconnect the electrical connector. 2 Remove the two parking aid radar sensor nuts. 3 Remove the radar sensor. All vehicles 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Sensor > Component Information > Diagrams C2090 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations View 151-12 (Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 9627 Pedal Positioning Switch: Diagrams C2089 C2235 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 9628 Pedal Positioning Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 9629 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 9630 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9636 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9637 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9638 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9639 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9640 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9641 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9642 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9643 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9644 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9645 Trailer Connector: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9646 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9647 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9648 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9649 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9650 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9651 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9652 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9653 Trailer Connector: Connector Views C2142 C4098 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9654 C4099 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9655 Trailer Connector: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 95-1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9656 95-2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9657 95-3 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. See: Diagrams/Components/Component Location Views Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair Trailer Hitch: Service and Repair TRAILER HITCH Removal and Installation WARNING: Do not permanently remove the trailer hitch. Always reinstall the hitch before delivery of the vehicle to the customer. Failure to follow this warning could increase the risk of injury in a rear end collision. 1. Raise and support the vehicle. 2. Remove the trailer hitch rear bumper cover trim panel. 3. Remove the trailer lighting plug cover and disconnect the electrical connector. 4. Remove the trailer lighting plug. 1 Position the plug away from the trailer hitch. 2 Disconnect the electrical connector. 3 Remove the trailer lighting plug. 5. Remove the trailer hitch. - Remove the 8 bolts. To install, tighten to 175 Nm (129 lb-ft). 6. NOTE: Do not reuse body support mounting fasteners. New fasteners must be installed for each fastener that has been removed or loosened. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions Trailer Lamps: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9665 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9666 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9667 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9668 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9669 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9670 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9671 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9672 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9673 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9674 Trailer Lamps: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9675 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9676 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9677 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9678 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9679 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9680 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9681 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9682 Trailer Lamps: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 95-1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9683 95-2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 9684 95-3 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. See: Diagrams/Components/Component Location Views Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Trailer Lamps: Initial Inspection and Diagnostic Overview INSPECTION AND VERIFICATION 1. Verify the customer concern. 2. Verify the exterior lighting system of the vehicle is operating correctly. If not, refer to the appropriate pinpoint test. See: Pinpoint Tests 3. Visually inspect the following for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical Central junction box (CJB) fuse(s): 10 (20A) (trailer tow parking lamps relay, trailer tow reversing lamps relay) - 13 (10A) (trailer tow battery charge relay coil) - 29 (30A) (trailer tow electric brake controller) - 36 (10A) (trailer tow RH stop/turn lamp) - 42 (10A) (trailer tow LH stop/turn lamp) - 106 (30A) (trailer tow battery charge relay) - Circuitry - Trailer - Trailer tow battery charge relay - Trailer tow parking lamps relay - Trailer tow reversing lamps relay - Trailer tow electric brake controller - CJB 4. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 5. If the concern is not visually evident, verify the symptom and GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9687 Trailer Lamps: Symptom Related Diagnostic Procedures Symptom Chart (Part 1) Symptom Chart (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9688 Trailer Lamps: Pinpoint Tests Test V: The Trailer Lamps Are Inoperative PINPOINT TEST V: THE TRAILER LAMPS ARE INOPERATIVE V1 Normal Operation Ground for the trailer tow lamps is provided through circuit 206 (WH). Possible Causes - Circuit 206 (WH) open - Trailer Test W: The Individual Trailer Lamp Is Inoperative - RH Trailer Turn/Stop Lamp PINPOINT TEST W: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - RH TRAILER TURN/STOP LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9689 W1-W2 Normal Operation Voltage for the trailer tow RH turn/stop lamp is provided by the central junction box (CJB) fuse 36 (10A) through circuit 64 (DG). Possible Causes - Fuse - Circuit 64 (DG) open - Trailer - CJB Test X: The Individual Trailer Lamp Is Inoperative - LH Trailer Turn/Stop Lamp PINPOINT TEST X: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - LH TRAILER TURN/STOP LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9690 X1-X2 Normal Operation Voltage for the trailer tow LH turn/stop lamp is provided by the central junction box (CJB) fuse 42 (10A) through circuit 52 (YE). Possible Causes - Fuse - Circuit 52 (YE) open - Trailer - CJB Test Y: The Trailer Lamps Are Inoperative - Trailer Parking Lamps PINPOINT TEST Y: THE TRAILER LAMPS ARE INOPERATIVE - TRAILER PARKING LAMPS Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9691 Y1-Y4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9692 Y4-Y6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9693 Y7 Normal Operation Voltage for the trailer tow parking lamps relay coil is supplied through circuit 14 (BN) when the vehicle parking lamps are on. Ground for the trailer tow parking lamps relay coil is supplied through circuit 57 (BK). Voltage for the trailer tow parking lamps relay supply is sent by the central junction box (CJB) fuse 10 (20A). When the trailer tow parking lamps relay is energized, voltage is routed to the trailer through circuit 962 (BN/WH). Possible Causes - Fuse - Circuit 14 (BN) open - Circuit 57 (BK) open - Circuit 962 (BN/WH) open - Trailer - Trailer tow parking lamps relay - CJB Test Z: The Trailer Lamps Are Inoperative - Trailer Reversing Lamps PINPOINT TEST Z: THE TRAILER LAMPS ARE INOPERATIVE - TRAILER REVERSING LAMPS Z1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9694 Z1-Z3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9695 Z3-Z4 Normal Operation The trailer tow reversing lamps relay is integral to the central junction box (CJB). Voltage for the trailer tow reversing lamps relay coil is supplied through circuit 140 (BK/PK) when the vehicle reversing lamps are on. Ground for the trailer tow reversing lamps relay coil is supplied through circuit 57 (BK). Voltage for the trailer tow reversing lamps relay supply is sent by the CJB fuse 10 (20A). When the trailer tow reversing lamps relay is energized, voltage is routed to the trailer through circuit 963 (BK/LG). Possible Causes - Fuse - Circuit 140 (BK/PK) open - Circuit 57 (BK) open - Circuit 963 (BK/LG) open - Trailer - CJB Tests AA: The Trailer Lamps Are On Continuously PINPOINT TEST AA: THE TRAILER LAMPS ARE ON CONTINUOUSLY Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9696 AA1-AA4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9697 AA4 Continued Normal Operation - Trailer Tow Parking Lamps When the trailer tow parking lamps relay is energized, the voltage is routed to the trailer through circuit 962 (BN/WH). Normal Operation - Trailer Tow Reversing Lamps The trailer tow reversing lamps relay is integral to the central junction box (CJB). When the trailer tow reversing lamps relay is energized, voltage is routed to the trailer through circuit 963 (BK/LG). Possible Causes - Circuit 962 (BN/WH) short to voltage - Circuit 963 (BK/LG) short to voltage - Trailer tow parking lamps relay - Trailer - CJB Tests AB: The Trailer Battery Charging Is Inoperative PINPOINT TEST AB: THE TRAILER BATTERY CHARGING IS INOPERATIVE AB1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9698 AB1-AB2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9699 AB3-AB5 Normal Operation Voltage for the trailer tow battery charge relay coil is supplied by the central junction box (CJB) fuse 13 (10A) when the ignition switch is in the RUN position. Ground for the trailer tow battery charge relay coil is supplied through circuit 57 (BK). Voltage for the trailer tow battery charge relay supply is supplied by the CJB fuse 106 (30A). When the trailer tow battery charge relay is energized, voltage is routed to the trailer through circuit 49 (OG). Possible Causes - Fuse - Circuit 49 (OG) open - Circuit 57 (BK) open - Trailer tow battery charge relay - Trailer - CJB Tests AC: The Trailer Electric Brakes Do Not Operate Correctly PINPOINT TEST AC: THE TRAILER ELECTRIC BRAKES DO NOT OPERATE CORRECTLY Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9700 AC1-AC2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9701 AC2-AC4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9702 AC5-AC6 Normal Operation Voltage for the trailer tow electric brake controller is supplied by the central junction box (CJB) fuse 29 (30A) through circuit 50 (RD). Ground for the trailer tow electric brake controller coil is supplied through circuit 206 (WH). Voltage input from the stoplamp switch is supplied through circuit 511 (LG). When the parking lamps are on, voltage for the trailer tow electric brake controller illumination is supplied through circuit 14 (BN). Voltage output from the trailer tow electric brake controller voltage to the trailer is sent through circuit 43 (DB). Possible Causes - Fuse - Circuit 14 (BN) open - Circuit 43 (DB) open or short to ground - Circuit 50 (RD) open - Circuit 206 (WH) open - Circuit 511 (LG) open - Trailer tow electric brake controller - Trailer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Page 9703 Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 9708 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Diagrams > Trailer Tow Relay, Parking Lamp C2240 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Diagrams > Trailer Tow Relay, Parking Lamp > Page 9711 C2110 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 9714 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 9715 Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Battery Charge Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 9716 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Locations > Page 9720 C2110 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Locations > Page 9721 Trailer Towing Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Locations > Page 9722 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9727 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9728 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9729 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9730 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9731 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9732 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9733 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9734 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9735 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9736 Trailer Connector: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9737 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9738 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9739 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9740 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9741 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9742 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9743 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9744 Trailer Connector: Connector Views C2142 C4098 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9745 C4099 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9746 Trailer Connector: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 95-1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9747 95-2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9748 95-3 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. See: Diagrams/Components/Component Location Views Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations Body Control Module: Locations VEHICLE SECURITY MODULE (VSM) View 151-17 (RH A-Pillar) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Page 9754 Body Control Module: Diagrams VEHICLE SECURITY MODULE (VSM) C2113a C2113b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Page 9755 C2113c Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) Body Control Module: Service and Repair Driver Seat Module (DSM) DRIVER SEAT MODULE (DSM) Removal and Installation CAUTION: - Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. - Prior to the removal of the module, it is necessary to upload module configuration information to the appropriate diagnostic equipment. This information needs to be downloaded into the new module once installed. 1. NOTE: The module is accessed with the seat fully in the UP position. Position the driver seat module forward to remove it from the bracket. 2. Disconnect the battery. 3. Disconnect the electrical connectors and remove the DSM. 4. CAUTION: Once the module is installed it is necessary to download the module configuration information from the diagnostic tool into the new module. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 9758 Body Control Module: Service and Repair Vehicle Security Module VEHICLE SECURITY MODULE Removal CAUTION: The steps included in the vehicle security module removal and installation procedure are critical to restoring the vehicle security and tire pressure monitoring systems to normal operation. A new vehicle security module is delivered in manufacturing mode with 6 pre-set diagnostic trouble codes (DTCs) related to the tire pressure monitoring system (TPMS). The presence of these DTCs requires the installation procedures be followed in order to clear the DTCs and enable normal vehicle security module operations. 1. NOTE: Prior to the removal of the vehicle security module, it is necessary to upload the module configuration information to the diagnostic tool. This information must be downloaded to the new vehicle security module after installation. Disconnect the battery. 2. Remove the pin-type retainer and the RH A-pillar lower trim panel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 9759 3. Remove the glove compartment. 4. Disconnect the 3 electrical connectors. 5. Remove the 2 screws and the vehicle security module. Installation 1. Position the vehicle security module and install the 2 screws. - Tighten the screws to 6 Nm (53 lb-in). 2. Connect the 3 electrical connectors. 3. Position the RH A-pillar lower trim panel and install the pin-type retainer. 4. Install the glove compartment 5. Connect the battery. 6. NOTE: When successful, this step provides the calibration necessary for vehicle security module operation and clears DTC B2477. The clearing of the DTC indicates the calibration data has been successfully downloaded to the vehicle security module. Download the vehicle security module configuration information from the diagnostic tool to the vehicle security module. 7. NOTE: When successful, this step clears DTCs B2868, B2869, B2870 and B2871. The clearing of these DTCs indicates the vehicle security module has recognized the tire pressure sensors during the training procedure. Train the tire pressure sensors. 8. Clear the DTCs. 9. NOTE: - DTC C2780 will not clear if any other DTCs are present in the vehicle security module. - This step is required to clear DTC C2780, allow the vehicle security module to exit the manufacturing mode, and to be sure there are no other concerns with the newly programmed vehicle security module. Carry out the vehicle security module on-demand self-test. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor > Component Information > Locations > Running Board Motor Assembly, Left View 151-15 (LH A-Pillar) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor > Component Information > Locations > Running Board Motor Assembly, Left > Page 9765 View 151-17 (RH A-Pillar) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor > Component Information > Diagrams > Running Board Motor Assembly, Left C3185 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor > Component Information > Diagrams > Running Board Motor Assembly, Left > Page 9768 C3186 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor > Component Information > Diagrams > Page 9769 Auxiliary Step / Running Board Motor: Service and Repair RETRACTABLE RUNNING BOARD MOTOR Removal and Installation 1. NOTE: If the retractable running board cannot be extracted, extend the running board by hand. Extend the retractable running board. 2. Disconnect the retractable running board motor electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor > Component Information > Diagrams > Page 9770 3. Remove the retractable running board motor. - Remove the bolts. To install, tighten to 5 Nm (44 lb-in). - Remove the cover and retractable running board motor. 4. Disconnect the retractable running board sensor wiring harness. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair Front Bumper Cover / Fascia: Service and Repair FRONT BUMPER COVER Expedition Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Page 9776 Navigator Exploded View Removal and Installation All vehicles 1. Remove the lower air deflector. - Remove the 8 pin-type retainers. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Page 9777 2. Remove the 2 front bumper cover lower pin-type retainers. 3. Remove the 3 front fender splash shield screws. 4. Remove the 2 front fender-to-front bumper cover bolts. - To install, tighten to 8 Nm (71 lb-in). Expedition 5. Disconnect the fog lamp electrical connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Page 9778 6. Remove the upper air deflector. 1 Remove the 8 pin-type retainers. 2 Remove the upper air deflector. 7. Remove the 2 bolts. 8. Release the front bumper cover clips and remove the front bumper cover. Navigator 9. Disconnect the fog lamp electrical connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Page 9779 10. Release the front bumper cover clips and remove the front bumper. All vehicles 11. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair Rear Bumper Cover / Fascia: Service and Repair REAR BUMPER COVER Exploded View Removal and Installation NOTE: Navigator shown, Expedition similar. 1. Remove the 5 rear fender splash shield bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Page 9784 2. Remove the rear 6 bumper cover nuts and bolts. 3. If equipped, disconnect the reverse parking aid electrical connector. 4. Remove the 2 rear bumper cover lower pin-type retainers. 5. Remove the liftgate trim. - Remove the 2 pin-type retainers. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Page 9785 6. Remove the rear bumper cover. - Remove the 5 pin-type retainers and 2 bolts. 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL PANEL GRILLE Removal and Installation 1. Remove the windshield wipers. 2. Remove the cowl grille seal. 3. Remove the pin-type retainer and left side cowl trim panel. - Disconnect the windshield washer tube. 4. Remove the right side cowl trim panel. 1 Disconnect the windshield washer tube. 2 Remove the pin-type retainer. 5. If necessary, adjust the windshield wiper arms. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 > Door Handle Front Door Exterior Handle: Service and Repair Door Handle EXTERIOR FRONT DOOR HANDLE Removal and Installation NOTE: The front door window glass must be completely raised. 1. Remove the front door trim panel. 2. Position the watershield aside. 3. Open the clip and disconnect the exterior door handle actuating rod. 4. If equipped, disconnect the door lock cylinder actuating rod from the lock cylinder. 5. NOTE: Push the exterior door handle out from the bottom surface of the handle. Remove the 2 nuts and the exterior front door handle. To install, tighten to 9 Nm (80 lb-in). 6. NOTE: Make sure the door handle and the front door handle rod is in a relaxed position and that the front door handle rod are all the way up before closing the clips. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 > Door Handle > Page 9798 Front Door Exterior Handle: Service and Repair Front Door Handles, Locks and Latches Exploded View FRONT DOOR HANDLES, LOCKS AND LATCHES - EXPLODED VIEW Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 > Door Handle > Page 9799 Part 2 Removal and Installation 1. For additional information, refer to the procedures. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Adjustments > Hinge Adjustment - Front Door, Fore and Aft Front Door Hinge: Adjustments Hinge Adjustment - Front Door, Fore and Aft HINGE ADJUSTMENT - FRONT DOOR, FORE AND AFT NOTE: Check the rear door hinge adjustment before adjusting the front door hinge. 1. Remove the 2 door striker bolts and door striker. 2. Remove the front fender. 3. Loosen the front door hinge-to-body bolts. 4. Adjust the front door alignment to specification. 5. Tighten the front door hinge-to-body bolts to 30 Nm (22 lb-ft). 6. Install the front fender. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Adjustments > Hinge Adjustment - Front Door, Fore and Aft > Page 9804 7. Install and adjust the door striker. - Tighten to 12 Nm (9 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Adjustments > Hinge Adjustment - Front Door, Fore and Aft > Page 9805 Front Door Hinge: Adjustments Hinge Adjustment - Front Door, Horizontal and Vertical HINGE ADJUSTMENT - FRONT DOOR, HORIZONTAL AND VERTICAL 1. Remove the 2 door striker bolts and door striker. 2. Loosen the front door hinge-to-front door bolts enough to permit movement of the door. 3. Adjust the front door alignment. 4. Tighten the front door hinge-to-front door bolts to 30 Nm (22 lb-ft). 5. Install and adjust the door striker. - Tighten to 12 Nm (9 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Front Door Handles, Locks and Latches - Exploded View Front Door Latch: Service and Repair Front Door Handles, Locks and Latches - Exploded View FRONT DOOR HANDLES, LOCKS AND LATCHES - EXPLODED VIEW Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Front Door Handles, Locks and Latches - Exploded View > Page 9810 Part 2 Removal and Installation 1. For additional information, refer to the procedures. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Front Door Handles, Locks and Latches - Exploded View > Page 9811 Front Door Latch: Service and Repair Front Door Latch FRONT DOOR LATCH Removal and Installation 1. NOTE: The door glass must be completely raised. Remove the front door trim panel. 2. Position the watershield aside. 3. If equipped, disconnect the door lock cylinder actuating rod from the lock cylinder. 4. Open the clip and disconnect the exterior door handle actuating rod. 5. Remove and discard the 3 bolts and position the front door latch aside. - To install, tighten to 9 Nm (80 lb-in). 6. Disconnect the front door lock actuator and the door ajar switch electrical connectors. 7. Release the interior door handle actuating cable and remove the front door latch. 1 Position the cable cover aside. 2 Release the conduit and the interior door handle actuating cable. 8. NOTE: Make sure the door handle and the front door handle rod is in a relaxed position and that the front door handle rod are all the way up before closing the clips. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair Front Door Panel: Service and Repair FRONT DOOR TRIM PANEL Removal and Installation NOTE: Left front door shown, right front similar. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Page 9815 1. Remove the window control switch plate. - Use the service notch and disconnect the electrical connectors. 2. Remove the door handle bezel. - Use service notch. 3. CAUTION: To avoid damage to the door trim panel, lift the door trim panel by pulling directly upward on the armrest to disengage the panel clips. Remove the 2 bolts and 3 screws and remove the door trim panel. Remove the finish cover to access the 2 center screws. - Disconnect the electrical connectors. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Glass: > 07-10-5 > May > 07 > Body - Front Door Window Scratched Front Door Window Glass: Customer Interest Body - Front Door Window Scratched TSB 07-10-5 05/28/07 FRONT DOOR SIDE GLASS SCRATCHED DUE TO COLLECTION OF DIRT/DEBRIS IN WARPED OUTER WINDOW MOLDING FORD: 2003-2007 Expedition 2005 Excursion 2005-2008 F-Super Duty LINCOLN: 2007 Navigator This article supersedes TSB 06-18-2 to update the vehicle model years, vehicle application and parts information. ISSUE Some 2005-2008 F-Super Duty, 2005 Excursion, 2003-2007 Expedition and 2007 Navigator vehicles may exhibit outer window molding weather strip assembly warping around the lower front window channel. The condition may be described as a warped or loose outer window molding. There may be a pucker or gap between the window beltline molding weather strip assembly and the window glass. This may result in dirt and debris collecting between the molding and the glass, and therefore scratching the side-window glass. ACTION Use the Service Procedure to replace the outer window molding and adjust the molding flange. SERVICE PROCEDURE 1. Lower the side door window completely. 2. Remove the outside mirror. 3. Remove the outer window molding weather strip assembly by lifting it up away from the flange (Figure 1). 4. Raise the side door glass completely. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Glass: > 07-10-5 > May > 07 > Body - Front Door Window Scratched > Page 9824 5. Measure the distance from inboard sur[ace of the door molding flange to outboard surface of the window glass (Figure 2). Distance from flange to glass should be between 5/8-3/4" (16-19 mm) for F-Super Duty and Excursion, and 3/16-7/16" (5-11 mm) for Expedition and Navigator. 6. Lower glass completely. 7. Adjust the door molding flange to meet the 5/8-3/4" (16-19 mm) dimension. Do not adjust flange more than 3/4" (19 mm) away from the glass. 8. Install a new lower window molding weather strip assembly. 9. Reinstall mirror. 10. If the side door glass has been scratched, replace the glass. Refer to Workshop Manual, Section 501-11. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Glass: > 07-10-5 > May > 07 > Body - Front Door Window Scratched > Page 9825 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071005A 2005-2008 F-Super Duty, 0.5 Hr. 2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005B 2005-2008 F-Super Duty, 0.9 Hr. 2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange Both Front Doors (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005C 2005-2008 F-Super Duty, 0.7 Hr. 2005 Excursion: Replace The Window Beltline Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Glass: > 07-10-5 > May > 07 > Body - Front Door Window Scratched > Page 9826 Molding Includes Time To Measure And Adjust Door Molding Flange, And Replace Window Glass: One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005D 2005-2008 F-Super Duty, 1.3 Hrs. 2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange, And Replace Window Glass Both Front Doors (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005E 2003-2007 Expedition, 0.6 Hr. 2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust Door Molding Flange: One Front Door (Do Not Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) 07100SF 2003-2007 Expedition, 1.1 Hrs. 2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust Door Molding Flange: Both Front Doors (Do Not Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) 071005G 2003-2007 Expedition, 0.9 Hr. 2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust Door Molding Flange And Replace Window Glass: One Front Door (Do Not Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) 071005H 2003-2007 Expedition, 1.7 Hrs. 2007 Navigator: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange And Replace Window Glass: Both Front Doors (Do Not Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Glass: > 07-10-5 > May > 07 > Body - Front Door Window Scratched > Page 9827 Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) DEALER CODING CONDITION BASIC PART NO. CODE 2521452 07 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 07-10-5 > May > 07 > Body - Front Door Window Scratched Front Door Window Glass: All Technical Service Bulletins Body - Front Door Window Scratched TSB 07-10-5 05/28/07 FRONT DOOR SIDE GLASS SCRATCHED DUE TO COLLECTION OF DIRT/DEBRIS IN WARPED OUTER WINDOW MOLDING FORD: 2003-2007 Expedition 2005 Excursion 2005-2008 F-Super Duty LINCOLN: 2007 Navigator This article supersedes TSB 06-18-2 to update the vehicle model years, vehicle application and parts information. ISSUE Some 2005-2008 F-Super Duty, 2005 Excursion, 2003-2007 Expedition and 2007 Navigator vehicles may exhibit outer window molding weather strip assembly warping around the lower front window channel. The condition may be described as a warped or loose outer window molding. There may be a pucker or gap between the window beltline molding weather strip assembly and the window glass. This may result in dirt and debris collecting between the molding and the glass, and therefore scratching the side-window glass. ACTION Use the Service Procedure to replace the outer window molding and adjust the molding flange. SERVICE PROCEDURE 1. Lower the side door window completely. 2. Remove the outside mirror. 3. Remove the outer window molding weather strip assembly by lifting it up away from the flange (Figure 1). 4. Raise the side door glass completely. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 07-10-5 > May > 07 > Body - Front Door Window Scratched > Page 9833 5. Measure the distance from inboard sur[ace of the door molding flange to outboard surface of the window glass (Figure 2). Distance from flange to glass should be between 5/8-3/4" (16-19 mm) for F-Super Duty and Excursion, and 3/16-7/16" (5-11 mm) for Expedition and Navigator. 6. Lower glass completely. 7. Adjust the door molding flange to meet the 5/8-3/4" (16-19 mm) dimension. Do not adjust flange more than 3/4" (19 mm) away from the glass. 8. Install a new lower window molding weather strip assembly. 9. Reinstall mirror. 10. If the side door glass has been scratched, replace the glass. Refer to Workshop Manual, Section 501-11. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 07-10-5 > May > 07 > Body - Front Door Window Scratched > Page 9834 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071005A 2005-2008 F-Super Duty, 0.5 Hr. 2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005B 2005-2008 F-Super Duty, 0.9 Hr. 2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange Both Front Doors (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005C 2005-2008 F-Super Duty, 0.7 Hr. 2005 Excursion: Replace The Window Beltline Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 07-10-5 > May > 07 > Body - Front Door Window Scratched > Page 9835 Molding Includes Time To Measure And Adjust Door Molding Flange, And Replace Window Glass: One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005D 2005-2008 F-Super Duty, 1.3 Hrs. 2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange, And Replace Window Glass Both Front Doors (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005E 2003-2007 Expedition, 0.6 Hr. 2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust Door Molding Flange: One Front Door (Do Not Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) 07100SF 2003-2007 Expedition, 1.1 Hrs. 2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust Door Molding Flange: Both Front Doors (Do Not Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) 071005G 2003-2007 Expedition, 0.9 Hr. 2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust Door Molding Flange And Replace Window Glass: One Front Door (Do Not Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) 071005H 2003-2007 Expedition, 1.7 Hrs. 2007 Navigator: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange And Replace Window Glass: Both Front Doors (Do Not Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 07-10-5 > May > 07 > Body - Front Door Window Scratched > Page 9836 Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) DEALER CODING CONDITION BASIC PART NO. CODE 2521452 07 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 9837 Front Door Window Glass: By Symptom Technical Service Bulletin # 07-10-5 Date: 070528 Body - Front Door Window Scratched TSB 07-10-5 05/28/07 FRONT DOOR SIDE GLASS SCRATCHED DUE TO COLLECTION OF DIRT/DEBRIS IN WARPED OUTER WINDOW MOLDING FORD: 2003-2007 Expedition 2005 Excursion 2005-2008 F-Super Duty LINCOLN: 2007 Navigator This article supersedes TSB 06-18-2 to update the vehicle model years, vehicle application and parts information. ISSUE Some 2005-2008 F-Super Duty, 2005 Excursion, 2003-2007 Expedition and 2007 Navigator vehicles may exhibit outer window molding weather strip assembly warping around the lower front window channel. The condition may be described as a warped or loose outer window molding. There may be a pucker or gap between the window beltline molding weather strip assembly and the window glass. This may result in dirt and debris collecting between the molding and the glass, and therefore scratching the side-window glass. ACTION Use the Service Procedure to replace the outer window molding and adjust the molding flange. SERVICE PROCEDURE 1. Lower the side door window completely. 2. Remove the outside mirror. 3. Remove the outer window molding weather strip assembly by lifting it up away from the flange (Figure 1). 4. Raise the side door glass completely. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 9838 5. Measure the distance from inboard sur[ace of the door molding flange to outboard surface of the window glass (Figure 2). Distance from flange to glass should be between 5/8-3/4" (16-19 mm) for F-Super Duty and Excursion, and 3/16-7/16" (5-11 mm) for Expedition and Navigator. 6. Lower glass completely. 7. Adjust the door molding flange to meet the 5/8-3/4" (16-19 mm) dimension. Do not adjust flange more than 3/4" (19 mm) away from the glass. 8. Install a new lower window molding weather strip assembly. 9. Reinstall mirror. 10. If the side door glass has been scratched, replace the glass. Refer to Workshop Manual, Section 501-11. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 9839 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071005A 2005-2008 F-Super Duty, 0.5 Hr. 2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005B 2005-2008 F-Super Duty, 0.9 Hr. 2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange Both Front Doors (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005C 2005-2008 F-Super Duty, 0.7 Hr. 2005 Excursion: Replace The Window Beltline Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 9840 Molding Includes Time To Measure And Adjust Door Molding Flange, And Replace Window Glass: One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005D 2005-2008 F-Super Duty, 1.3 Hrs. 2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange, And Replace Window Glass Both Front Doors (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005E 2003-2007 Expedition, 0.6 Hr. 2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust Door Molding Flange: One Front Door (Do Not Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) 07100SF 2003-2007 Expedition, 1.1 Hrs. 2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust Door Molding Flange: Both Front Doors (Do Not Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) 071005G 2003-2007 Expedition, 0.9 Hr. 2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust Door Molding Flange And Replace Window Glass: One Front Door (Do Not Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) 071005H 2003-2007 Expedition, 1.7 Hrs. 2007 Navigator: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange And Replace Window Glass: Both Front Doors (Do Not Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 9841 Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) DEALER CODING CONDITION BASIC PART NO. CODE 2521452 07 Disclaimer Technical Service Bulletin # 07-10-5 Date: 070528 Body - Front Door Window Scratched TSB 07-10-5 05/28/07 FRONT DOOR SIDE GLASS SCRATCHED DUE TO COLLECTION OF DIRT/DEBRIS IN WARPED OUTER WINDOW MOLDING FORD: 2003-2007 Expedition 2005 Excursion 2005-2008 F-Super Duty LINCOLN: 2007 Navigator This article supersedes TSB 06-18-2 to update the vehicle model years, vehicle application and parts information. ISSUE Some 2005-2008 F-Super Duty, 2005 Excursion, 2003-2007 Expedition and 2007 Navigator vehicles may exhibit outer window molding weather strip assembly warping around the lower front window channel. The condition may be described as a warped or loose outer window molding. There may be a pucker or gap between the window beltline molding weather strip assembly and the window glass. This may result in dirt and debris collecting between the molding and the glass, and therefore scratching the side-window glass. ACTION Use the Service Procedure to replace the outer window molding and adjust the molding flange. SERVICE PROCEDURE 1. Lower the side door window completely. 2. Remove the outside mirror. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 9842 3. Remove the outer window molding weather strip assembly by lifting it up away from the flange (Figure 1). 4. Raise the side door glass completely. 5. Measure the distance from inboard sur[ace of the door molding flange to outboard surface of the window glass (Figure 2). Distance from flange to glass should be between 5/8-3/4" (16-19 mm) for F-Super Duty and Excursion, and 3/16-7/16" (5-11 mm) for Expedition and Navigator. 6. Lower glass completely. 7. Adjust the door molding flange to meet the 5/8-3/4" (16-19 mm) dimension. Do not adjust flange more than 3/4" (19 mm) away from the glass. 8. Install a new lower window molding weather strip assembly. 9. Reinstall mirror. 10. If the side door glass has been scratched, replace the glass. Refer to Workshop Manual, Section 501-11. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 9843 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071005A 2005-2008 F-Super Duty, 0.5 Hr. 2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005B 2005-2008 F-Super Duty, 0.9 Hr. 2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange Both Front Doors (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005C 2005-2008 F-Super Duty, 0.7 Hr. 2005 Excursion: Replace Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 9844 The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange, And Replace Window Glass: One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005D 2005-2008 F-Super Duty, 1.3 Hrs. 2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange, And Replace Window Glass Both Front Doors (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005E 2003-2007 Expedition, 0.6 Hr. 2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust Door Molding Flange: One Front Door (Do Not Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) 07100SF 2003-2007 Expedition, 1.1 Hrs. 2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust Door Molding Flange: Both Front Doors (Do Not Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) 071005G 2003-2007 Expedition, 0.9 Hr. 2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust Door Molding Flange And Replace Window Glass: One Front Door (Do Not Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) 071005H 2003-2007 Expedition, 1.7 Hrs. 2007 Navigator: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange And Replace Window Glass: Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 9845 Both Front Doors (Do Not Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) DEALER CODING CONDITION BASIC PART NO. CODE 2521452 07 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > Page 9846 Front Door Window Glass: Service and Repair FRONT DOOR WINDOW GLASS Removal and Installation All vehicles 1. Remove the front door trim panel. 2. Remove the front door weathershield. Expedition 3. NOTE: Driver side shown, passenger side similar. Connect the window control switch. All vehicles 4. Lower the window glass to access the 2 window glass to regulator bolts. 5. Remove the inside glass weatherstrip. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > Page 9847 6. Remove the front door glass channel bolt and position aside the channel. - To install, tighten to 11 Nm (8 lb-ft). 7. Remove the window glass-to-regulator bolts and front door window glass. - To install, tighten to 11 Nm (8 lb-ft). 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Locations > Left Front View 151-28 (Driver Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Locations > Left Front > Page 9852 View 151-29 (Passenger Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Diagrams > Left Front Front Door Window Motor: Diagrams Left Front C518 C540 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Diagrams > Left Front > Page 9855 C608 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair Front Door Window Regulator: Service and Repair WINDOW REGULATOR - FRONT DOOR Removal and Installation All vehicles 1. Remove the front door trim panel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Page 9859 2. Remove the screws and the front door speaker. - Disconnect the electrical connector. 3. Remove the front door weathershield. Expedition 4. NOTE: Driver side shown, passenger side similar. Connect the window control switch. All vehicles 5. Lower the window glass to access the 2 window glass-to-regulator bolts. Expedition Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Page 9860 6. NOTE: Driver side shown, passenger side similar. Disconnect the window control switch. All vehicles 7. Remove the window glass-to-regulator bolts and front door window glass. - To install, tighten to 11 Nm (8 lb-ft). 8. NOTE: Secure the front window glass in the full UP position. Secure the front window glass with tape to the front door frame. 9. Position the interior door handle aside. 1 Remove the cable conduit fitting from the carrier assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Page 9861 2 Lift upward on the interior door handle retaining bracket and pivot the interior door handle out of the bracket. 3 Remove the cable from the door handle. 10. Release the crash sensor harness pin-type retainers. 11. Position the front door window regulator harness aside. 1 Disconnect the electrical connectors. 2 Release the pin-type retainers. 12. Remove the front window regulator. 1 Loosen the 2 hanger bolts. 2 Remove the front window regulator bolts and front top run channel bolt. To install, tighten to 11 Nm (8 lb-ft). 13. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 > Door Handle Rear Door Exterior Handle: Service and Repair Door Handle EXTERIOR REAR DOOR HANDLE Removal and Installation NOTE: The rear door window glass must be completely raised. 1. Remove the rear door trim panel. 2. Position the watershield aside. 3. Remove the childproof door lock cover. 4. Open the clip and disconnect the exterior door handle actuating rod. 5. NOTE: Push the exterior door handle out from the bottom surface of the handle. Remove the 2 nuts and the exterior rear door handle. To install, tighten to 9 Nm (80 lb-in). 6. NOTE: Make sure the door handle and the rear door handle rod are in a relaxed position and the rear door handle rod is all the way up before closing the clips. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 > Door Handle > Page 9868 Rear Door Exterior Handle: Service and Repair Rear Door Handles, Locks and Latches - Exploded View REAR DOOR HANDLES, LOCKS AND LATCHES - EXPLODED VIEW Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 > Door Handle > Page 9869 Part 2 Removal and Installation 1. For additional information, refer to the procedures. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Adjustments > Hinge Adjustment - Door, Rear, Fore, Aft and Tilt Rear Door Hinge: Adjustments Hinge Adjustment - Door, Rear, Fore, Aft and Tilt HINGE ADJUSTMENT - DOOR, REAR, FORE, AFT AND TILT 1. Position the front seat in the full forward position. 2. Remove the 2 door striker bolts and door striker. 3. Remove the lower B-pillar trim panel. 4. Remove the B-pillar weathershield. 5. Loosen the hinge-to-B-pillar nuts enough to allow movement of the rear door. 6. Adjust the rear door until it is uniform to adjacent panels. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Adjustments > Hinge Adjustment - Door, Rear, Fore, Aft and Tilt > Page 9874 7. Tighten the hinge-to-B-pillar nuts to 30 Nm (22 lb-ft). 8. Install the B-pillar weathershield. 9. Install the lower B-pillar trim panel. 10. Install the door striker. - Tighten to 12 Nm (9 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Adjustments > Hinge Adjustment - Door, Rear, Fore, Aft and Tilt > Page 9875 Rear Door Hinge: Adjustments Hinge Adjustment - Door, Rear, In, Out, Up and Down HINGE ADJUSTMENT - DOOR, REAR, IN, OUT, UP AND DOWN 1. Remove the 2 door striker bolts and door striker. 2. Loosen the hinge-to-door bolts enough to allow door movement. 3. Adjust the door until it is uniform to adjacent panels. 4. Tighten the hinge-to-door bolts to 30 Nm (22 lb-ft). 5. Install the door striker. - Tighten to 12 Nm (9 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Rear Door Handles, Locks and Latches - Exploded View Rear Door Latch: Service and Repair Rear Door Handles, Locks and Latches - Exploded View REAR DOOR HANDLES, LOCKS AND LATCHES - EXPLODED VIEW Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Rear Door Handles, Locks and Latches - Exploded View > Page 9880 Part 2 Removal and Installation 1. For additional information, refer to the procedures. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Rear Door Handles, Locks and Latches - Exploded View > Page 9881 Rear Door Latch: Service and Repair Rear Door Latch REAR DOOR LATCH Removal and Installation NOTE: The rear door window glass must be completely raised. 1. Remove rear door trim panel. 2. Position the watershield aside. 3. Remove the childproof door lock cover. 4. Open the clip and disconnect the exterior door handle actuating rod. 5. Remove and discard the 3 bolts and position the rear door latch aside. - To install, tighten to 9 Nm (80 lb-in). 6. Disconnect the rear door lock actuator and ajar switch electrical connectors. 7. Release the interior door cable and remove the rear door latch. 1 Position the cable cover aside. 2 Release the conduit and the interior door handle actuating cable. 8. NOTE: Make sure the door handle and the rear door handle rod are in a relaxed position and the rear door handle rod is all the way up before closing the clips. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair Rear Door Panel: Service and Repair REAR DOOR TRIM PANEL Removal and Installation NOTE: Left rear door shown, right rear similar. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Page 9885 1. If equipped with power windows, remove the window control switch plate. - Use the service notch. 2. Remove the door handle bezel. - Use the service notch. 3. CAUTION: To avoid damage to the door trim panel, lift the door trim panel by pulling directly upward on the armrest to disengage the panel clips. Remove the 2 bolts and 3 screws, and remove the door trim panel. Remove the finish cover to access the 2 center screws. - If equipped, disconnect the electrical connector. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 Rear Door Window Glass: Service and Repair Rear Door Window Glass REAR DOOR WINDOW GLASS Removal and Installation 1. Remove the rear door trim panel. 2. Position back the rear door weathershield. 3. Connect the window control switch. 4. Lower the window glass to access the 2 window glass to regulator bolts. 5. Remove the inside glass weatherstrip. 6. Remove the rear door glass channel bolts. - To install, tighten to 11 Nm (8 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 > Page 9890 7. Remove the window glass to regulator bolts and rear door window glass. - To install, tighten to 11 Nm (8 lb-ft). 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 > Page 9891 Rear Door Window Glass: Service and Repair Rear Door Window Glass - Stationary REAR DOOR WINDOW GLASS - STATIONARY Removal and Installation 1. Remove the rear door window glass. 2. Remove the rear door exterior glass moulding. 3. Remove the rear door glass top run. 4. Remove the rear door stationary glass screw. 5. Remove the stationary rear door glass. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair Rear Door Window Regulator: Service and Repair WINDOW REGULATOR - REAR DOOR Removal and Installation 1. Remove the rear door trim panel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Page 9895 2. Remove the rear door speaker. 1 Remove the screws. 2 Disconnect the electrical connector. 3 Remove the speaker. 3. Remove the rear door weathershield. 4. Connect the window control switch. 5. Lower the window glass to access the 2 window glass-to-regulator bolts. 6. Disconnect the window control switch. 7. Remove the window glass-to-regulator bolts and rear door window glass. - To install, tighten to 11 Nm (8 lb-ft). 8. NOTE: Secure the rear window glass in the full UP position. Secure the rear window glass with tape to the front door frame. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Page 9896 9. Disconnect the rear door window regulator electrical connectors. 10. Position the interior door handle aside. - Lift upward on the interior door handle retaining bracket and pivot the interior door handle out of the bracket. 11. Remove the rear door window regulator assembly. - Remove the bolts. To install, tighten to 11 Nm (8 lb-ft). 12. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch Hood Latch: Service and Repair Hood Latch HOOD LATCH Removal and Installation All vehicles 1. Remove the 8 pin-type retainers and the upper radiator sight shield. Expedition 2. Remove the 2 bolts and the hood latch. - To install, tighten to 12 Nm (9 lb-ft). 3. Release the hood latch cable from the hood latch. Navigator 4. Remove the screw and position the secondary hood latch release handle aside. - To install, tighten to 5 Nm (44 lb-in). 5. Remove the 2 bolts and the hood latch. - To install, tighten to 12 Nm (9 lb-ft). 6. Release the primary and secondary hood latch cables from the hood latch. All vehicles 7. To install, reverse the removal procedure. - Verify the hood latch engages the striker in the latched position (secondary). - Verify the hood latch engages the striker in the fully latched position (primary). - Adjust the hood latch as necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch > Page 9902 Hood Latch: Service and Repair Hood Latch and Components - Exploded View Hood Latch and Components - Exploded View Removal and Installation 1. For additional information, refer to the procedures. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release > Component Information > Service and Repair > Hood Latch and Components - Exploded View Hood Latch Release: Service and Repair Hood Latch and Components - Exploded View Hood Latch and Components - Exploded View Removal and Installation 1. For additional information, refer to the procedures. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release > Component Information > Service and Repair > Hood Latch and Components - Exploded View > Page 9907 Hood Latch Release: Service and Repair Hood Latch Release Handle HOOD LATCH RELEASE HANDLE Removal and Installation NOTE: The Navigator secondary hood latch release handle and cable is removed as part of the hood latch. 1. Remove the hood latch. 2. Remove the hood latch release handle and cable screw. - To install, tighten to 5 Nm (44 lb-ft). 3. Release the cable guides and push the cable through the dash panel and remove the hood latch release handle and cable. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 LIFTGATE WINDOW GLASS Removal and Installation Window glass assembly 1. Remove the rear window wiper motor. 2. Disconnect the rear window defrost electrical connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Page 9912 3. CAUTION: - The liftgate glass must be supported when removing and installing the liftgate assist cylinders. - Do not extend the socket clips more than 2.0 mm (0.08 in) or failure of the socket can occur. Disconnect the 2 liftgate glass assist cylinders. 1 Insert a screwdriver blade under the socket clip and lift. 2 Gently pull the socket off the ball stud. Window glass assembly or hinge assembly 4. Remove the liftgate glass hinge-to-body fasteners and remove the glass. - To install, tighten to 12 Nm (9 lb-ft). Window hinge assembly 5. Remove the liftgate glass to hinge fasteners and remove the glass. - Apply Threadlock 262 to the liftgate glass to hinge fasteners during installation. - To install, tighten to 8 Nm (71 lb-in). Window glass assembly or window hinge assembly 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Locations View 151-19 (Left Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Locations > Page 9916 Power Trunk / Liftgate Control Module: Diagrams C4174a C4174b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Locations > Page 9917 C4174c C4174d Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Locations > Page 9918 Power Trunk / Liftgate Control Module: Service and Repair POWER LIFTGATE MODULE Removal and Installation NOTE: Prior to removal of the power liftgate module, it is necessary to upload module configuration information to a diagnostic tool. This information needs to be downloaded into the new power liftgate module once installed. 1. Remove the rear quarter trim panel. 2. Remove the power liftgate module. 1 Disconnect the electrical connectors. 2 Remove the nut. To install, tighten to 11 Nm (8 lb-ft). 3. NOTE: Once the new power liftgate module is installed, it is necessary to download the module configuration information from the diagnostic tool into the new power liftgate module. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Liftgate Glass Actuator View 151-32 (Liftgate) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Liftgate Glass Actuator > Page 9923 View 151-32 (Liftgate) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Diagrams > Liftgate Glass Actuator C4040 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Diagrams > Liftgate Glass Actuator > Page 9926 Power Trunk / Liftgate Lock Actuator: Diagrams Liftgate Lock Actuator C457 C4185 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Locations View 151-32 (Liftgate) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Page 9930 C4039 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge > Component Information > Adjustments Trunk / Liftgate Hinge: Adjustments HINGE ADJUSTMENT - LIFTGATE 1. Loosen the liftgate hinge to liftgate bolts. 2. Adjust the liftgate alignment. 3. NOTE: The bolt washers must make full contact with the liftgate bracket when tightened. Tighten the liftgate hinge-to-liftgate bolts to 12 Nm (9 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Service and Repair > Liftgate Handle, Lock and Latch - Exploded View Trunk / Liftgate Handle: Service and Repair Liftgate Handle, Lock and Latch - Exploded View LIFTGATE HANDLE, LOCK AND LATCH - EXPLODED VIEW Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Service and Repair > Liftgate Handle, Lock and Latch - Exploded View > Page 9938 Part 2 Removal and Installation 1. For additional information, refer to the procedures. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Service and Repair > Liftgate Handle, Lock and Latch - Exploded View > Page 9939 Trunk / Liftgate Handle: Service and Repair Liftgate Release Handle LIFTGATE RELEASE HANDLE Removal and Installation All Vehicles 1. Remove the liftgate trim panel. 2. Position the watershield aside. Expedition 3. Remove the 2 nuts and position the liftgate release handle aside. - To install, tighten to 5 Nm (44 lb-in). 4. Release the liftgate latch actuating cable from the liftgate release handle and remove the handle. Navigator 5. Remove the 2 liftgate release handle nuts. - To install, tighten to 9 Nm (80 lb-in). 6. NOTE: Release the clips on the inside of license plate housing. Remove the license plate housing. Disconnect the electrical connectors. - Remove the 6 nuts. - To install, tighten to 5 Nm (44 lb-in). 7. Release the liftgate release handle from the liftgate. 8. Disconnect the electrical connector and release the liftgate latch actuating cable from the liftgate release handle and remove the handle. All vehicles 9. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Handle, Lock and Latch - Exploded View Trunk / Liftgate Latch: Service and Repair Liftgate Handle, Lock and Latch - Exploded View LIFTGATE HANDLE, LOCK AND LATCH - EXPLODED VIEW Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Handle, Lock and Latch - Exploded View > Page 9944 Part 2 Removal and Installation 1. For additional information, refer to the procedures. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Handle, Lock and Latch - Exploded View > Page 9945 Trunk / Liftgate Latch: Service and Repair Liftgate Latch LIFTGATE LATCH Removal and Installation All vehicles 1. Remove the liftgate trim panel. 2. Position the watershield aside. Vehicles with manual liftgate 3. Disconnect the liftgate latch electrical connectors. Vehicles with power liftgate 4. CAUTION: Be careful not to kink the liftgate latch actuating cable while disconnecting it. Disconnect the liftgate latch. 1 Disconnect the liftgate latch actuating cable. 2 Release the door lock actuator rod. 3 Release the actuating rod. 4 Disconnect the electrical connector. All vehicles 5. Remove and discard the 3 bolts and position the liftgate latch aside. - To install, tighten to 12 Nm (9 lb-ft). Vehicles with manual liftgate 6. CAUTION: Be careful not to kink the liftgate latch actuating cable while disconnecting it from the latch. Disconnect the liftgate latch actuating cable and remove the liftgate latch. Vehicles with power liftgate Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Handle, Lock and Latch - Exploded View > Page 9946 7. CAUTION: Be careful not to kink the liftgate latch control cable while disconnecting it from the latch. Disconnect the liftgate latch control cable and remove the liftgate latch. All vehicles 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Handle, Lock and Latch - Exploded View > Page 9947 Trunk / Liftgate Latch: Service and Repair Liftgate Latch - Window LIFTGATE LATCH - WINDOW Removal and Installation 1. Remove the liftgate trim panel. 2. Open the liftgate window glass. 3. Disconnect the liftgate window latch electrical connector. 4. Remove the 2 bolts and the liftgate window latch. - To install, tighten to 8 Nm (71 lb-in). 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Handle, Lock and Latch - Exploded View > Page 9948 Trunk / Liftgate Latch: Service and Repair Liftgate Latch Remote Control LIFTGATE LATCH REMOTE CONTROL Removal and Installation NOTE: The liftgate latch remote control is available with power liftgate only. 1. Remove the liftgate trim panel. 2. Position the watershield aside. 3. CAUTION: Be careful not to kink the liftgate latch actuating cable while disconnecting it from the latch. Disconnect the liftgate latch. 1 Release the liftgate latch actuator rod. 2 Disconnect the liftgate latch actuating cable. 4. Remove 3 bolts and position the liftgate latch remote control aside. - To install, tighten to 11 Nm (8 lb-in). 5. Disconnect the electrical connectors and remove the liftgate latch remote control. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Locations > Liftgate Cinching Motor View 151-32 (Liftgate) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Locations > Liftgate Cinching Motor > Page 9953 View 151-23 (Roof) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Locations > Liftgate Cinching Motor > Page 9954 View 151-32 (Liftgate) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Diagrams > Liftgate Cinching Motor C4188 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Diagrams > Liftgate Cinching Motor > Page 9957 Trunk / Liftgate Motor: Diagrams Liftgate Drive Motor Assembly, Left C997a C997b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Diagrams > Liftgate Cinching Motor > Page 9958 C996 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Diagrams > Liftgate Cinching Motor > Page 9959 C4189 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Diagrams > Page 9960 Trunk / Liftgate Motor: Service and Repair POWER LIFTGATE MOTOR Removal and Installation 1. Disconnect the battery ground cable and wait at least one minute. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Diagrams > Page 9961 2. NOTE: RH side shown, LH side similar. Position the front and rear door seals aside. 3. Remove the C-pillar trim panel. 4. Remove the D-pillar trim panel. 5. CAUTION: To prevent damage to the coat hanger retainer, use a 3/16-inch flat-blade screwdriver for this step. Remove the 4 coat hooks. Open the access cover. - Insert a screwdriver into the slot and rotate. 6. If equipped with rear climate control, remove the center pin-type retainers. 7. Remove the rear pin-type retainers. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Diagrams > Page 9962 8. CAUTION: To avoid damaging the headliner, do not crease or bend it. Partially lower the headliner to access the power liftgate motor. 9. Remove the upper liftgate trim. 10. Position the wiring harness aside. 11. Remove the power liftgate motor to liftgate bolts. - To install, tighten to 11 Nm (8 lb-ft). 12. Disconnect the electrical connectors and remove the power liftgate motor bolts. - To install, tighten to 11 Nm (8 lb-ft). 13. Remove the power liftgate motor pivot bolt. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Diagrams > Page 9963 - To install, tighten to 9 Nm (80 lb-in). 14. Slide the power liftgate motor assembly forward and remove the power liftgate motor. 15. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Service and Repair > Liftgate Handle, Lock and Latch - Exploded View Trunk / Liftgate Solenoid: Service and Repair Liftgate Handle, Lock and Latch - Exploded View LIFTGATE HANDLE, LOCK AND LATCH - EXPLODED VIEW Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Service and Repair > Liftgate Handle, Lock and Latch - Exploded View > Page 9968 Part 2 Removal and Installation 1. For additional information, refer to the procedures. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Service and Repair > Liftgate Handle, Lock and Latch - Exploded View > Page 9969 Trunk / Liftgate Solenoid: Service and Repair Liftgate Latch Actuator LIFTGATE LATCH ACTUATOR Special Tool(s) Special Tool(s) Removal and Installation 1. Remove the liftgate trim panel. 2. Position the watershield aside. 3. Release the liftgate latch actuator rod from the liftgate latch. 4. Disconnect the liftgate latch actuator electrical connector. 5. Remove the rivet and the liftgate latch actuator. 6. To install, reverse the removal procedure. - Use the Heavy Duty Riveter to install the new rivet. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Striker > Component Information > Service and Repair Trunk / Liftgate Striker: Service and Repair REAR WINDOW STRIKER AND WIPER PIVOT SHAFT ASSEMBLY Removal 1. Remove the rear wiper pivot arm. 2. Remove the dust boot cover. 3. Remove the nut and the rear window glass handle. 4. Remove the nuts and the rear window striker and wiper pivot shaft assembly. Installation 1. Remove the liftgate trim panel. 2. NOTE: An audible click should be heard as the striker engages the latch. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Striker > Component Information > Service and Repair > Page 9973 Push the rear window wiper striker and pivot shaft assembly into the wiper motor. The pivot shaft pin should be aligned with the hole in the motor disc. 3. Install the rear window wiper motor alignment tool. If installing a new rear wiper motor, one is provided with the motor assembly. 1 Make sure the alignment tool fits over the motor disc and striker assembly. 2 Make sure the alignment tool clips are securely engaged. 4. Carefully close the liftgate glass. 5. Open the liftgate. Install the rear window wiper striker and wiper pivot arm mounting assembly nuts. Tighten to 6 Nm (53 lb-in). 6. Remove the rear window wiper motor alignment tool. 7. Close the liftgate. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Striker > Component Information > Service and Repair > Page 9974 8. Install the rear window wiper pivot shaft nut and handle. Tighten to 18 Nm (13 lb-ft). 9. Install the dust boot cover. 10. NOTE: This step makes sure that the wiper motor is in the PARK position. Turn the rear window wiper switch ON and allow the motor to operate for at least one cycle. Turn the rear window wiper switch to OFF. 11. Install the rear wiper pivot arm onto the rear window wiper motor shaft. 1 Position the wiper pivot arm onto the rear window wiper motor shaft. 2 Tighten the nut to 15 Nm (11 lb-ft). 3 Install the cover. 12. Open the liftgate. 13. Install the liftgate trim panel. 14. Test the liftgate and liftgate glass for normal operation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Liftgate Fork Bolt/Detent Switch View 151-32 (Liftgate) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Liftgate Fork Bolt/Detent Switch > Page 9979 View 151-32 (Liftgate) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Liftgate Fork Bolt/Detent Switch > Page 9980 View 151-23 (Roof) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Diagrams > Liftgate Fork Bolt/Detent Switch C4190 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Diagrams > Liftgate Fork Bolt/Detent Switch > Page 9983 C4187 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Diagrams > Liftgate Fork Bolt/Detent Switch > Page 9984 C9000 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL PANEL GRILLE Removal and Installation 1. Remove the windshield wipers. 2. Remove the cowl grille seal. 3. Remove the pin-type retainer and left side cowl trim panel. - Disconnect the windshield washer tube. 4. Remove the right side cowl trim panel. 1 Disconnect the windshield washer tube. 2 Remove the pin-type retainer. 5. If necessary, adjust the windshield wiper arms. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Fender > Front Fender > System Information > Service and Repair Front Fender: Service and Repair FENDER - EXPEDITION Exploded View Removal and Installation NOTE: Left side shown, right side similar. 1. Remove the front fender splash shield. 2. Remove the 2 front fender-to-front bumper cover bolts. - To install, tighten to 8 Nm (71 lb-in). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Fender > Front Fender > System Information > Service and Repair > Page 9993 3. Remove the front fender-to-radiator support bolt. - To install, tighten to 12 Nm (9 lb-ft). 4. Remove the 2 front fender lower bolts. - To install, tighten to 12 Nm (9 lb-ft). 5. Remove the foam insulator. - Remove the pin-type retainer. 6. Remove the 2 front fender inner bolts. - To install, tighten to 12 Nm (9 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Fender > Front Fender > System Information > Service and Repair > Page 9994 7. Loosen the headlamp retaining bolt. 8. Remove the headlamp. - Remove the bolts and disconnect the electrical connectors. 9. Remove the 2 front fender front bolts. - To install, tighten to 8 Nm (71 lb-in). 10. Remove the cowl panel grille. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Fender > Front Fender > System Information > Service and Repair > Page 9995 11. Remove the front fender. 1 Remove the 4 bolts. 2 Remove the front fender. To install, tighten to 12 Nm (9 lb-ft). 12. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Locations > Page 10000 Body / Frame Mount Bushing: Description and Operation FRAME AND BODY MOUNTING Frame Components Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Locations > Page 10001 Spare Tire Winch The frame is made up of 2 steel boxed side rails and crossmembers, which are welded to the 2 side rails. The transmission crossmember is bolted to the side rails. The side welded rails and crossmembers are not replaced separately. The service kits available for the frame are the following: - RH front horn replacement kit (5D058) - LH front horn replacement kit (5D059) - Front bumper bracket replacement kit (17N775) - 1B crossmember replacement kit (5C075) - Transmission crossmember replacement kit (5059) Refer to the instructions included in the kits for installation instructions. Frame Mounted Heat Shields All frame mounted heat shields are torqued to 15 Nm (11 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 Body / Frame Mount Bushing: Service and Repair Body Support - Number 1 BODY SUPPORT - NUMBER 1 No.1 Body Support Mount Removal and Installation NOTE: Left side shown, right side similar. 1. Remove the body mount bolt. - To install, tighten to 80 Nm (59 lb-ft). 2. Loosen the remaining body mount bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 10004 3. Raise the vehicle body enough to remove the body mount bolts and body mount. - To install, tighten to 55 Nm (41 lb-ft). 4. NOTE: - No lubricants of any kind are to be used during body mount installation. - Do not reuse body mount fasteners. New fasteners must be installed for each fastener that has been removed or loosened. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 10005 Body / Frame Mount Bushing: Service and Repair Body Support - Number 2 and Number 3 BODY SUPPORT - NUMBER 2 AND NUMBER 3 No.2 Body Support Mount No.3 Body Support Mount Removal and Installation NOTE: Body mount No. 2, left side shown, all others similar. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 10006 Upper and lower body support mount 1. Remove the body mount bolt and lower body mount. - To install, tighten to 80 Nm (59 lb-ft). Upper body mount 2. Loosen the remaining body mount bolts. 3. Raise the vehicle body enough to remove the upper body mount. Upper and lower body mount 4. NOTE: - No lubricants of any kind are to be used during body mount installation. - Do not reuse body mount fasteners. New fasteners must be installed for each fastener that has been removed or loosened. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 10007 Body / Frame Mount Bushing: Service and Repair Body Support - Number 4 BODY SUPPORT - NUMBER 4 No.4 Body Mount Removal and Installation NOTE: Left side shown, right side similar. 1. Remove the liftgate scuff plate. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 10008 2. Remove the body mount bolt cover. 3. Remove the body mount nut. - To install, tighten to 55 Nm (41 lb-ft). 4. Loosen the remaining body mount bolts. 5. Raise the vehicle body enough to remove the body mount bolts. - To install, tighten to 55 Nm (41 lb-ft). 6. NOTE: - No lubricants of any kind are to be used during body mount installation. - Do not reuse body mount fasteners. New fasteners must be installed for each fastener that has been removed or loosened. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 10009 Body / Frame Mount Bushing: Service and Repair Body Support - Radiator Support BODY SUPPORT - RADIATOR SUPPORT Radiator Support Mount Removal and Installation NOTE: Left side shown, right side similar. Upper and lower body mount 1. Remove the lower radiator body mount. 1 Remove the lower radiator body mount bolt. 2 Remove the lower radiator body mount. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 10010 - To install, tighten to 80 Nm (59 lb-ft). Upper body mount 2. Loosen the remaining body mount bolts. 3. Raise the vehicle body enough to remove the upper body mount. Upper and lower body mount 4. NOTE: - No lubricants of any kind are to be used during body mount installation. - Do not reuse body mount fasteners. New fasteners must be installed for each fastener that has been removed or loosened. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Spot Welds - Rear Cross Member & Side Members Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Spot Welds - Rear Cross Member & Side Members > Page 10016 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Spot Welds - Rear Cross Member & Side Members > Page 10017 Rear Cross-Member: Service and Repair Transmission Support Crossmember TRANSMISSION SUPPORT CROSSMEMBER Transmission Support Crossmember - Exploded View Removal and Installation 1. Raise and support the vehicle. 2. If equipped, remove the skid plate fasteners and skid plate. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Spot Welds - Rear Cross Member & Side Members > Page 10018 3. Remove the LH and RH exhaust heat shield-to-crossmember fasteners. 4. Remove the 2 transmission mount nuts. - To install, tighten to 103 Nm (76 lb-ft). 5. Support the transmission. 6. NOTE: Mark the transmission crossmember next to the edge of the frame bracket to make sure the crossmember is installed in the same position it was removed from. Remove the 4 transmission crossmember bolts and transmission crossmember. To install, tighten to 90 Nm (66 lb-ft). 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair Trailer Hitch: Service and Repair TRAILER HITCH Removal and Installation WARNING: Do not permanently remove the trailer hitch. Always reinstall the hitch before delivery of the vehicle to the customer. Failure to follow this warning could increase the risk of injury in a rear end collision. 1. Raise and support the vehicle. 2. Remove the trailer hitch rear bumper cover trim panel. 3. Remove the trailer lighting plug cover and disconnect the electrical connector. 4. Remove the trailer lighting plug. 1 Position the plug away from the trailer hitch. 2 Disconnect the electrical connector. 3 Remove the trailer lighting plug. 5. Remove the trailer hitch. - Remove the 8 bolts. To install, tighten to 175 Nm (129 lb-ft). 6. NOTE: Do not reuse body support mounting fasteners. New fasteners must be installed for each fastener that has been removed or loosened. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations > Page 10025 C2110 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations > Page 10026 Trailer Towing Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations > Page 10027 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair Grille: Service and Repair RADIATOR GRILLE Removal and Installation 1. Remove the front bumper cover. 2. Remove the clips and remove the front grille. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair Arm Rest: Service and Repair SEAT ARMREST - SECOND ROW Removal and Installation 1. To access the armrest locking metal clip, pull the armrest material back on the top side of the armrest for access to the release clip. 2. CAUTION: To remove armrests, do not pull them off with force. The locking metal clip will be damaged and a new armrest will need to be installed. NOTE: Armrest removed to show detail of release button mechanism. Use a tool such as a flat-bladed screwdriver to push the release button at the hinge point. The clip will release and the armrest will slide off the pin. 3. CAUTION: To install armrests, do not push them on with force. The locking metal clip will be damaged and a new armrest will need to be installed. To install, reverse the removal procedure. To install the armrest, push the release button and slide the armrest on the pin. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Description and Operation > Console - Floor, Front Console: Description and Operation Console - Floor, Front CONSOLE - FLOOR, FRONT The front floor console may consist of the following components: - A/C integral control assembly - A/C register (upper) - Auxiliary A/C controls - Auxiliary power point - Center console finish panel - Console finish panel mat - Compact disc (CD) player mounting bracket - CD player compartment trim panel - Digital audio compact disc player - Shift lever (Navigator) - Window control switch panel (Navigator) - Navigation system display module - Navigation system module - Video cassette player Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Description and Operation > Console - Floor, Front > Page 10039 Console: Description and Operation Console - Floor, Rear CONSOLE - FLOOR, REAR The rear console consists of the following components: - Armrest - Cup holders - Storage bin Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Description and Operation > Console - Floor, Front > Page 10040 Console: Description and Operation Console - Overhead CONSOLE - OVERHEAD There are 2 versions of the overhead console, with and without the roof opening panel. The overhead console with the roof opening panel may contain the following: - Climate controls (optional) - Map lamps/switches - Roof opening panel switch - Rear quarter window switches (optional) The overhead console without the roof opening panel may contain the following: - Climate controls (optional) - Glasses storage bin - Map lamps/switches - Rear quarter window switches (optional) - Storage bin Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console - Front Console: Service and Repair Floor Console - Front FLOOR CONSOLE - FRONT Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console - Front > Page 10043 Part 2 Removal and Installation 1. Position the front seat forward. 2. Remove the 2 front floor console rear bolts. - To install, tighten to 7 Nm (62 lb-in). 3. Position the front seats rearward. 4. Disconnect the battery. 5. Remove the console finish panel. 1 Remove the mat. 2 Remove the screw. - Disconnect the electrical connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console - Front > Page 10044 6. Disconnect the front floor console electrical connectors. 1 Loosen the electrical connector bolt. To install, tighten to 5 Nm (44 lb-in). 2 Disconnect the electrical connector. 7. Remove the floor console. 1 Remove the screws. 2 Remove the bolts. To install, tighten to 12 Nm (9 lb-ft). 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console - Front > Page 10045 Console: Service and Repair Floor Console - Rear FLOOR CONSOLE - REAR Removal and Installation Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console - Front > Page 10046 1. Remove the rear floor console. 1 Open the front bin. 2 Remove the cup holder. 3 Remove the bolts. To install, tighten to 12 Nm (9 lb-ft). 2. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Depowering and Repowering SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING Depowering Procedure WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the electrical connector on a safety canopy module. Doing so can result in safety canopy deployment. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the RH side of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse 19 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located at the bottom of the hood latch support bracket. The first row side impact sensors (if equipped) are located in the first row doors, behind the door trim panel. The second row side impact sensors (if equipped) are located at or near the base of the C-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install the RCM fuse 19 (10A) to the CJB and close the cover. 4. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10052 Connect the battery ground cable. 5. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a diagnostic tool. Deactivation and Reactivation SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION Special Tool(s) Special Tool(s) Deactivation WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the connectors on the safety canopy module. Doing so can result in safety canopy module deployment. - To reduce the risk of personal injury, do not use any memory saver devices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10053 NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the RH side of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse 19 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located at the bottom of the hood latch support bracket. The first row side impact sensors (if equipped) are located in the first row doors, behind the door trim panel. The second row side impact sensors (if equipped) are located at or near the base of the C-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 7. Remove the 2 steering wheel back cover plugs (1 shown). 8. Remove the 2 driver air bag module bolts (1 shown). Expedition Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10054 9. Remove the driver air bag module. 1 Release the 2 retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector before disconnecting. 2 Release the 2 retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector before disconnecting. 3 Disconnect the horn switch electrical connector. 4 Remove the driver air bag module. Navigator 10. Disconnect the driver air bag module. - Release the 2 tabs on each driver air bag module electrical connector and disconnect them. Label each driver air bag module electrical connector before disconnecting. 11. Release the tab and disconnect the driver air bag module accessories electrical connector at the top of the clockspring and remove the driver air bag module. All vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10055 12. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of the steering column. 13. While pushing in on the 2 glove compartment door tabs, position the glove compartment downward. 14. NOTE: Expedition shown, Navigator similar. Through the glove compartment opening, release the tab and disconnect the passenger air bag module electrical connector. 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Vehicles with safety canopies Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10056 16. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or if it does not remain closed, install a new shoulder safety belt guide cover. Remove the second row passenger side safety belt guide. 1 Release the retaining tab at each side and open the safety belt guide cover. 2 Remove the nut. 3 Remove the second row passenger side safety belt guide. 17. Remove the passenger side C-pillar trim panel. 1 Separate the weather-stripping along the passenger side C-pillar trim panel. 2 Remove the bolt cover and bolt. 3 Pull out to release the retainers and remove the passenger side C-pillar trim panel. 18. Disconnect the passenger side safety canopy electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10057 19. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy electrical connector. 20. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or if it does not remain closed, install a new shoulder safety belt guide cover. Remove the second row driver side safety belt guide. 1 Release the retaining tab at each side and open the safety belt guide cover. 2 Remove the nut. 3 Remove the second row driver side safety belt guide. 21. Remove the driver side C-pillar trim panel. 1 Separate the weather-stripping along the driver side C-pillar trim panel. 2 Remove the bolt cover and bolt. 3 Pull out to release the retainers and remove the driver side C-pillar trim panel. 22. Disconnect the driver side safety canopy electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10058 23. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy electrical connector. All vehicles 24. Install the RCM fuse 19 (10A) to the CJB. 25. Connect the battery ground cable. Reactivation All vehicles 1. Remove the RCM fuse 19 (10A) from the CJB. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles with safety canopies 3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy electrical connector. 4. Connect the driver side safety canopy electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10059 5. WARNING: Anytime the safety canopy module has deployed, the headliner, and all A, B, and C pillar upper trim panels and attaching hardware must be replaced along with any other damaged components and hardware. Failure to do so may result in personal injury in the event of a safety canopy module deployment. Install the driver side C-pillar trim panel. 1 Position the driver side C-pillar trim panel and push in, engaging the retainers. 2 Install the bolt and bolt cover. Tighten to 11 Nm (8 lb-ft). 3 Install the weather-stripping along the driver side C-pillar trim panel. 6. NOTE: - Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or if it does not remain closed, install a new shoulder safety belt guide cover. - Make sure the safety belt is not twisted prior to installation. Install the second row driver side safety belt guide. 1 Position the second row driver side safety belt guide. 2 Install the nut. Tighten to 40 Nm (30 lb-ft). 3 Close the safety belt guide cover. Verify the safety belt retractor operates without excessive effort or binding. 7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10060 8. Connect the passenger side safety canopy electrical connector. 9. WARNING: Anytime the safety canopy module has deployed, the headliner, and all A, B, and C pillar upper trim panels and attaching hardware must be replaced along with any other damaged components and hardware. Failure to do so may result in personal injury in the event of a safety canopy module deployment. Install the passenger C-pillar trim panel. 1 Position the passenger side C-pillar trim panel and push in, engaging the retainers. 2 Install the bolt and bolt cover. Tighten to 11 Nm (8 lb-ft). 3 Install the weather-stripping along the passenger side C-pillar trim panel. 10. NOTE: - Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or if it does not remain closed, install a new shoulder safety belt guide cover. - Make sure the safety belt is not twisted prior to installation. Install the second row passenger side safety belt guide. 1 Position the second row passenger side safety belt guide. 2 Install the nut. Tighten to 40 Nm (30 lb-ft). 3 Close the safety belt guide cover. Verify the safety belt retractor operates without excessive effort or binding. All vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10061 11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. 12. NOTE: Expedition shown, Navigator similar. Connect the passenger air bag module electrical connector. 13. Close the glove compartment. 14. Remove the restraint system diagnostic tools from the clockspring electrical connector at the top of the steering column. Navigator 15. Connect the driver air bag module accessories electrical connector to the connector end at the top of the clockspring. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10062 16. CAUTION: The clockspring electrical connectors are unique and cannot be reversed when connected to the driver air bag module. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Connect the driver air bag module electrical connectors as noted during removal. Position the driver air bag module to the steering wheel. Expedition 17. Position the driver air bag module to the steering wheel. 1 Connect the horn switch electrical connector. 2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when connected to the driver air bag module. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Connect the driver air bag module electrical connectors as noted during removal. 3 Position the driver air bag module to the steering wheel. All vehicles 18. Install the 2 driver air bag module bolts (1 shown). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10063 19. Install the 2 steering wheel back cover plugs (1 shown). 20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse 19 (10A) to the CJB and close the cover. 23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a diagnostic tool. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10064 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure PROVE OUT PROCEDURE Turn the ignition switch from the OFF to the ON position and visually monitor the air bag indicator with all SRS components connected or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an SRS fault is present, the air bag indicator will: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair Glove Compartment: Service and Repair GLOVE COMPARTMENT Removal and Installation 1. CAUTION: Forcing the glove compartment past the stops will damage the dampener. Open the glove compartment. 2. Disconnect the dampener. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Page 10068 3. Release the stops. 4. Remove the screws and the glove compartment. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair Headliner: Service and Repair HEADLINER Removal and Installation All vehicles 1. Disconnect the battery ground cable and wait at least one minute. 2. Position aside the front and rear door seals. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 10072 3. If equipped, remove the roof opening panel trim. 4. Remove the A-pillar trim panels. - Remove the bolt covers and bolts. 5. Remove the 2 pushpin retainers from the A-pillar post. 6. Open and lower the glove compartment. 7. Remove the pushpin retainer and disconnect the electronic compass/auto dimming rearview mirror connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 10073 8. If equipped, remove the electronic compass sensor. 9. If equipped, disconnect the auto-dimming mirror electrical connector. 10. Remove the 2 sun visors and visor clips. 1 Remove the 8 screws. 2 Remove the 2 sun visors and visor clips. If equipped, disconnect the electrical connectors. 11. If equipped, remove the overhead console. 12. If equipped, remove the DVD player. 13. Remove the upper B-pillar trim panel. 14. Remove the C-pillar trim panel. 15. Position aside the RH quarter trim panel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 10074 - Remove the pushpins. - Disconnect the electrical connectors. 16. Position aside the LH quarter trim panel. - Disconnect the electrical connector. 17. Remove the D-pillar trim panel. 18. CAUTION: To prevent damage to the coat hanger retainer, use a 3/16-inch flat-blade screwdriver for this step. Remove the 4 coat hooks. Open the access cover. - Insert a screwdriver into the slot and rotate. 19. Disconnect the 2 electrical connectors at the right side C-pillar and 1 electrical connector at the left side C-pillar. Vehicles equipped with rear climate control 20. Remove the center pin-type retainers. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 10075 21. Remove the rear pin-type retainers. 22. Tilt the headliner to release the vent duct. All vehicles 23. Remove the headliner. 24. To install, reverse the removal procedure. - Transfer parts as necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel Trim Panel: Service and Repair A-Pillar Trim Panel A-PILLAR TRIM PANEL Removal and Installation 1. Remove the 2 front assist handle covers. 2. Remove the 2 bolts. - To install, tighten to 5 Nm (44 lb-in). 3. NOTE: Carefully rotate the A-pillar trim panel during this step. Pry the A-pillar trim panel to remove. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 10080 Trim Panel: Service and Repair B-Pillar Trim Panel B-PILLAR TRIM PANEL Removal and Installation NOTE: Left side shown, right side similar. Upper and lower 1. NOTE: - Position the shoulder safety belt guide to the lowest position. - Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or the cover does not remain closed, install a new shoulder safety belt guide cover. Remove the shoulder safety belt guide. 1 Position the shoulder safety belt guide cover up. 2 Remove the safety belt guide nut. To install, tighten to 40 Nm (30 lb-ft). 3 Remove the shoulder safety belt guide. 2. Remove the upper B-pillar trim panel. 1 Remove the bolt cover and bolt. To install, tighten to 8 Nm (71 lb-in). 2 Remove the upper B-pillar trim panel by pulling outward to release the clips. Lower 3. Remove the front and rear door scuff plates. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 10081 4. Position the lower B-pillar trim panel aside. 5. Remove the front safety belt anchor bolt. - To install, tighten to 40 Nm (30 lb-ft). 6. Feed the safety belt through the lower B-pillar trim panel and remove. Upper and lower 7. To install, reverse the removal procedure. - When installing the upper B-pillar trim panel, insert the safety belt guide slide into the upper B-pillar trim panel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 10082 Trim Panel: Service and Repair C-Pillar Trim Panel C-PILLAR TRIM PANEL Removal and Installation NOTE: Right side shown, left side similar. 1. NOTE: - Position the shoulder safety belt guide to the lowest position. - Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or the cover does not remain closed, install a new shoulder safety belt guide cover. Remove the shoulder safety belt guide. 1 Position the shoulder safety belt cover up. 2 Remove the safety belt guide nut. To install, tighten to 40 Nm (30 lb-ft). 3 Remove the shoulder safety belt guide. 2. Remove the C-pillar trim panel. 1 Remove the bolt cover and bolt. To install, tighten to 8 Nm (71 lb-in). 2 Remove the C-pillar trim panel by pulling outward to release the retainers. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 10083 Trim Panel: Service and Repair D-Pillar Trim Panel D-PILLAR TRIM PANEL Removal and Installation NOTE: Right side with power vent windows and power liftgate shown, all others similar. 1. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or cover does not remain closed, install a new shoulder safety belt guide cover. Remove the shoulder safety belt guide. 1 Position the shoulder safety guide cover up. 2 Remove the safety belt guide nut. To install, tighten to 40 Nm (30 lb-ft). 3 Remove the shoulder safety belt guide. 2. Remove rear upper headliner trim panel. 3. Remove the D-pillar trim panel. 1 Disengage the upper clip by pulling downward. 2 Unseat the D-pillar trim panel and rotate forward to remove. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 10084 Trim Panel: Service and Repair A-Pillar Trim Panel A-PILLAR TRIM PANEL Removal and Installation 1. Remove the 2 front assist handle covers. 2. Remove the 2 bolts. - To install, tighten to 5 Nm (44 lb-in). 3. NOTE: Carefully rotate the A-pillar trim panel during this step. Pry the A-pillar trim panel to remove. 4. To install, reverse the removal procedure. B-Pillar Trim Panel B-PILLAR TRIM PANEL Removal and Installation NOTE: Left side shown, right side similar. Upper and lower 1. NOTE: - Position the shoulder safety belt guide to the lowest position. - Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or the cover does not remain closed, install a new shoulder safety belt guide cover. Remove the shoulder safety belt guide. 1 Position the shoulder safety belt guide cover up. 2 Remove the safety belt guide nut. To install, tighten to 40 Nm (30 lb-ft). 3 Remove the shoulder safety belt guide. 2. Remove the upper B-pillar trim panel. 1 Remove the bolt cover and bolt. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 10085 - To install, tighten to 8 Nm (71 lb-in). 2 Remove the upper B-pillar trim panel by pulling outward to release the clips. Lower 3. Remove the front and rear door scuff plates. 4. Position the lower B-pillar trim panel aside. 5. Remove the front safety belt anchor bolt. - To install, tighten to 40 Nm (30 lb-ft). 6. Feed the safety belt through the lower B-pillar trim panel and remove. Upper and lower 7. To install, reverse the removal procedure. - When installing the upper B-pillar trim panel, insert the safety belt guide slide into the upper B-pillar trim panel. C-Pillar Trim Panel C-PILLAR TRIM PANEL Removal and Installation NOTE: Right side shown, left side similar. 1. NOTE: - Position the shoulder safety belt guide to the lowest position. - Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or the cover does not remain closed, Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 10086 install a new shoulder safety belt guide cover. Remove the shoulder safety belt guide. 1 Position the shoulder safety belt cover up. 2 Remove the safety belt guide nut. To install, tighten to 40 Nm (30 lb-ft). 3 Remove the shoulder safety belt guide. 2. Remove the C-pillar trim panel. 1 Remove the bolt cover and bolt. To install, tighten to 8 Nm (71 lb-in). 2 Remove the C-pillar trim panel by pulling outward to release the retainers. 3. To install, reverse the removal procedure. D-Pillar Trim Panel D-PILLAR TRIM PANEL Removal and Installation NOTE: Right side with power vent windows and power liftgate shown, all others similar. 1. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or cover does not remain closed, install a new shoulder safety belt guide cover. Remove the shoulder safety belt guide. 1 Position the shoulder safety guide cover up. 2 Remove the safety belt guide nut. To install, tighten to 40 Nm (30 lb-ft). 3 Remove the shoulder safety belt guide. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 10087 2. Remove rear upper headliner trim panel. 3. Remove the D-pillar trim panel. 1 Disengage the upper clip by pulling downward. 2 Unseat the D-pillar trim panel and rotate forward to remove. 4. To install, reverse the removal procedure. Interior Trim - Exploded View INTERIOR TRIM - EXPLODED VIEW Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 10088 Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 10089 Part 2 Removal and Installation 1. For additional information, refer to the procedures. Liftgate Trim Panel LIFTGATE TRIM PANEL Removal and Installation 1. Open the liftgate glass and remove the scrivets. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 10090 2. Open the liftgate and remove the upper liftgate trim panel. - Pull lower corners toward the center on both sides and pull down along the top. 3. Remove the assist handle. 1 Remove the screws. 2 Remove the assist handle. 4. Remove the lower liftgate trim panel. 1 Hold the trim panel at the center area and slightly pull on the center clips to allow a tool to access the clips. 2 Release the 12 clips 2 to 3 at a time, starting from the right side working to the left side. 3 Once all the clips are released, slide the liftgate trim panel forward and down, away from the sheet metal. 5. To install, reverse the removal procedure. Rear Quarter Trim Panel REAR QUARTER TRIM PANEL Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 10091 Removal and Installation 1. Remove the C-pillar trim panel. 2. Remove the D-pillar trim panel. 3. Remove the liftgate scuff plate by pulling upward. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 10092 4. Remove the rear floor loadspace trim panel. 5. Remove the floor jack assembly. 6. Remove the pin-type retainers and pull back the carpeting. 7. Remove the 2 bolts and the loadspace trim panel by pulling upward. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 10093 8. Remove the third row seat safety belt anchor bolt. - To install, tighten to 40 Nm (30 lb-ft). 9. Remove the rear quarter trim panel pin-type retainer. 10. Remove the second row safety belt anchor. - To install, tighten to 40 Nm (30 lb-ft). 11. Remove the rear door scuff plate by pulling upward. 12. NOTE: The seat back must not be folded completely down, as the quarter trim panel will not have enough clearance to be removed. Fold the seat back of the third row seat downward so that the top edge of the seat back is positioned within approximately 203 mm (8 in) of the full DOWN position. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 10094 13. Remove the rear quarter trim panel. - Disengage the rear clip on the base of the trim panel first, by pulling the bottom rear edge toward the center of the vehicle. - Disengage the remaining clips. - If equipped, disconnect the power point and power third row seat switch electrical connector at the rear. 14. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair Door Lock Cylinder: Service and Repair DOOR LOCK CYLINDER Removal and Installation NOTE: Individual lock cylinders are repaired by discarding the inoperative lock cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current code of the vehicle. 1. Remove the exterior front door handle. 2. Remove the retainer and the front door lock cylinder. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 10105 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 10106 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Page 10107 View 151-28 (Driver Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Page 10108 C500 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Service and Repair > Remote Keyless Entry Keypad Code Programming Keyless Entry Key-Pad: Service and Repair Remote Keyless Entry Keypad Code Programming REMOTE KEYLESS ENTRY KEYPAD CODE PROGRAMMING 1. Enter the permanent factory remote keyless entry (RKE) keypad code. 2. Press the 1/2 button within 5 seconds to activate the programming mode. Holding the 1/2 button for more than 2 seconds after activation erases the stored customer code. The doors lock, then unlock, confirming the code is erased. The existing code does not need to be erased to program a new code. 3. Within 5 seconds, enter the new 5-digit RKE keypad code. The doors lock and unlock to confirm the new code is programmed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Service and Repair > Remote Keyless Entry Keypad Code Programming > Page 10111 Keyless Entry Key-Pad: Service and Repair Autolock and Horn Chirp Programming AUTOLOCK AND HORN CHIRP PROGRAMMING 1. Close all the doors. 2. Confirm that the ignition switch is in the OFF position. 3. Turn the ignition switch from OFF to RUN. 4. NOTE: Steps 4 through 8 must be carried out within 30 seconds. Press the power door lock UNLOCK button 3 times. 5. Turn the ignition switch from RUN to OFF. 6. Press the power door lock UNLOCK button 3 times. 7. Turn the ignition switch from OFF to RUN. 8. Verify the horn chirps. This indicates the system is in the enable/disable mode is ready to accept program changes. 9. Press the power door lock UNLOCK button 1 time to toggle the autolock/relock feature OFF. 10. Press the power door lock LOCK button once to enter the command. 11. Verify the horn chirps 1 time. There should only be 1 chirp indicating that autolock/relock feature is disabled. If 1 chirp is heard, followed by a longer sound of the horn, the autolock/relock feature has just been enabled. Return to Step 9. 12. Turn the ignition switch to the OFF position to exit the enable/disable mode. 13. Exit the vehicle and verify the horn chirps once to indicate that a feature has been changed and that autolock/relock is disabled. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Service and Repair > Remote Keyless Entry Keypad Code Programming > Page 10112 Keyless Entry Key-Pad: Service and Repair Remote Keyless Entry Keypad REMOTE KEYLESS ENTRY KEYPAD Removal and Installation 1. Remove the exterior mirror. 2. Disconnect the RKE keypad electrical connector. 3. Remove the front door window glass. 4. CAUTION: Damage to the base moulding may occur during the removal procedure. Remove the front door window base moulding. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Service and Repair > Remote Keyless Entry Keypad Code Programming > Page 10113 5. Remove the RKE keypad. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair Keyless Entry Transmitter: Service and Repair REMOTE KEYLESS ENTRY TRANSMITTER PROGRAMMING NOTE: - All remote keyless entry (RKE) transmitters must be programmed at the same time. - Programming (or reprogramming) of the RKE transmitters can be accomplished using a diagnostic tool or by carrying out the following steps: 1. The vehicle must be electronically unlocked before entering program mode using the door lock control switch while the driver door is open. 2. Turn the ignition switch from the OFF to the RUN position 8 times within 10 seconds, with the eighth turn ending in RUN. If the module successfully enters program mode, it locks and then unlocks all the doors. 3. Within 20 seconds, press any button on an RKE transmitter, and the doors lock and then unlock to confirm that each RKE transmitter is programmed. Repeat this step for each RKE transmitter. 4. If the door locks do not respond for any RKE transmitter, wait several seconds and press the button again. If the door locks still fail to respond, refer to Inspection and Verification. (Make sure that no more than the maximum number of RKE transmitters are attempted to be programmed.) See: Power Locks/Testing and Inspection/Initial Inspection and Diagnostic Overview/Inspection and Verification 5. Exiting the programming mode is accomplished if one of the following occurs: - The key transitions to the OFF position. - 20 seconds have passed since entering programming mode or since the last RKE transmitter was programmed. - The maximum number (6) of RKE transmitters have been programmed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Lock Actuator, Right Front View 151-29 (Passenger Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Lock Actuator, Right Front > Page 10122 View 151-28 (Driver Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Lock Actuator, Right Front > Page 10123 View 151-30 (Left Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Lock Actuator, Right Front > Page 10124 View 151-31 (Right Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Actuator, Left Front C525 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Actuator, Left Front > Page 10127 C603 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Actuator, Left Front > Page 10128 C704 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Actuator, Left Front > Page 10129 C804 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Front Door Handles, Locks and Latches - Exploded View Power Door Lock Actuator: Service and Repair Front Door Handles, Locks and Latches - Exploded View FRONT DOOR HANDLES, LOCKS AND LATCHES - EXPLODED VIEW Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Front Door Handles, Locks and Latches - Exploded View > Page 10132 Part 2 Removal and Installation 1. For additional information, refer to the procedures. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Front Door Handles, Locks and Latches - Exploded View > Page 10133 Power Door Lock Actuator: Service and Repair Front Door Lock Actuator FRONT DOOR LOCK ACTUATOR Removal and Installation 1. Remove the front door latch. 2. Release the locking tab and remove the front door lock actuator. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Front Door Handles, Locks and Latches - Exploded View > Page 10134 Power Door Lock Actuator: Service and Repair Rear Door Handles, Locks and Latches - Exploded View REAR DOOR HANDLES, LOCKS AND LATCHES - EXPLODED VIEW Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Front Door Handles, Locks and Latches - Exploded View > Page 10135 Part 2 Removal and Installation 1. For additional information, refer to the procedures. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Front Door Handles, Locks and Latches - Exploded View > Page 10136 Power Door Lock Actuator: Service and Repair Rear Door Lock Actuator REAR DOOR LOCK ACTUATOR Removal and Installation 1. Remove the rear door latch. 2. Release the locking tab and remove the rear door lock actuator. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side View 151-29 (Passenger Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side > Page 10141 View 151-28 (Driver Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side Power Door Lock Switch: Diagrams Door Lock Switch, Driver Side C505 C541 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side > Page 10144 Power Door Lock Switch: Diagrams Door Lock Switch, Passenger Side C605 C632 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 10145 Power Door Lock Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 10146 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations View 151-26 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 10152 Memory Positioning Module: Diagrams C341a C341b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 10153 C341c C341d Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations View 151-28 (Driver Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 10157 C503 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 10158 Seat Memory Switch: Testing and Inspection SWITCH - MEMORY SET Memory Set Switch Remove the memory set switch. Measure the resistance between the indicated terminals while pressing the requested switches. The resistance should be less than 5 ohms for each switch position. If the resistance is not less than 5 ohms for each switch, install a new switch; otherwise, return to the calling pinpoint test. NOTE: Refer to multimeter user's manual for testing diodes. To check the memory set switch LED, connect the positive meter lead to terminal 7 and the negative lead to terminal 1. 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, install a new switch; otherwise, return to the calling pinpoint test. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Service and Repair > Exterior Mirror Motor Synchronization Power Mirror Motor: Service and Repair Exterior Mirror Motor Synchronization EXTERIOR MIRROR MOTOR SYNCHRONIZATION NOTE: - This procedure must be performed any time the power folding mirrors are manually folded IN or OUT, or if the position of the mirror case has been moved without using the mirror control switch. - If the power folding mirrors are folded or unfolded continuously (6 to 10 cycles), the power lockout feature will disable the system for 2 minutes to prevent damage to the power fold motors. After 2 minutes have elapsed, normal operation will resume. 1. Set the mirror control switch to the CENTER position. NOTE: It may be necessary to cycle the power folding mirrors IN or OUT up to 4 times before they are synchronized. 2. Use the mirror control switch (press rearward) to automatically cycle the power folding mirrors IN and OUT 4 times. 3. When an audible popping sound is heard, the power folding mirror motors are synchronized. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Service and Repair > Exterior Mirror Motor Synchronization > Page 10163 Power Mirror Motor: Service and Repair Exterior Mirrors - Exploded View EXTERIOR MIRRORS - EXPLODED VIEW Removal and Installation 1. For additional information, refer to the procedures. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Service and Repair > Exterior Mirror Motor Synchronization > Page 10164 Power Mirror Motor: Service and Repair Exterior Mirror Motor EXTERIOR MIRROR MOTOR Removal and Installation NOTE: If equipped with power folding mirrors, they must be synchronized any time the mirrors have been folded or unfolded without using the mirror control switch. 1. Remove the mirror glass. 2. Remove the 3 exterior mirror motor screws and exterior mirror motor. - Disconnect the electrical connectors. 3. To install, reverse the removal procedure. - If equipped with power folding mirrors, must be synchronized. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations View 151-28 (Driver Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 10168 Power Mirror Switch: Diagrams C527 C577 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 10169 Power Mirror Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 10170 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 10171 Power Mirror Switch: Service and Repair EXTERIOR MIRROR CONTROL SWITCH Removal and Installation All vehicles 1. Remove the driver front door trim panel. Navigator 2. Depress the locking tabs and remove the exterior mirror control switch. Expedition Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 10172 3. Remove the exterior mirror control switch. 1 Depress the locking tabs. 2 Remove the exterior mirror control switch. All vehicles 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest for Paint: > 07-2-9 > Feb > 07 > Body - Paint Bubbles Around Liftgate Trim Paint: Customer Interest Body - Paint Bubbles Around Liftgate Trim TSB 07-2-9 02/05/07 PAINT BUBBLES AROUND LIFTGATE TRIM FORD: 2003-2006 Expedition LINCOLN: 2003-2006 Navigator ISSUE Some 2003-2006 Expedition and Navigator vehicles may experience paint bubbling or lifting around the trim area on the liftgate. This can occur when the trim part moves on the paint surface because of climate temp changes and/or owner operation. Overtime these trim parts can rub through the paint surface and cause corrosion to start developing between the aluminum gate and paint. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Paint resurfacing will be necessary to correct the paint bubbling concern. 2. Add Mylar tape to the backside edge of the following liftgate trim parts, the license plate bucket for Navigator (Figure 1) and the license lamp applique for Expedition (Figure 2). The Mylar tape will act as a friction barrier between the paint surface and the trim components. 3. Make sure that the backside of the trim pieces listed in Step 2 are clean of any contaminates. This can be done by wiping the surface with a 50% solution of isopropyl alcohol and water. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest for Paint: > 07-2-9 > Feb > 07 > Body - Paint Bubbles Around Liftgate Trim > Page 10182 4. Apply the Mylar tape to the backside edge of the trim component. It may be necessary to trim the tape after its been applied for a clean fit. 5. After applying the Mylar tape, follow installation procedure for each part as listed in the appropriate Workshop Manual, Section 501. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 070209A 2003-2006 Expedition: 1.3 Hrs. Install Mylar Tape To The Backside Edge Of The License Plate Applique, Include Time To Detrim (Do Not Use With P42D) 070209B 2003-2006 Navigator: 1.1 Hrs. Install Mylar Tape To The Backside Edge Of The License Plate Bucket, Include Time To Detrim (Do Not Use With P42D) 070209C 2003-2006 Expedition: 2.4 Hrs. Additional Time To Paint Liftgate. To Be Used With Operation A In This TSB (Includes Time For P101 Basic Paint) (Do Not Use With P42) 070209C 2003-2006 Navigator: 2.2 Hrs. Additional Time To Paint Liftgate. To Be Used With Operation B In This TSB (Includes Time For P101 Basic Paint) (Do Not Use With P42) DEALER CODING CONDITION BASIC PART NO. CODE 78404C42 D7 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 07-2-9 > Feb > 07 > Body - Paint Bubbles Around Liftgate Trim Paint: All Technical Service Bulletins Body - Paint Bubbles Around Liftgate Trim TSB 07-2-9 02/05/07 PAINT BUBBLES AROUND LIFTGATE TRIM FORD: 2003-2006 Expedition LINCOLN: 2003-2006 Navigator ISSUE Some 2003-2006 Expedition and Navigator vehicles may experience paint bubbling or lifting around the trim area on the liftgate. This can occur when the trim part moves on the paint surface because of climate temp changes and/or owner operation. Overtime these trim parts can rub through the paint surface and cause corrosion to start developing between the aluminum gate and paint. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Paint resurfacing will be necessary to correct the paint bubbling concern. 2. Add Mylar tape to the backside edge of the following liftgate trim parts, the license plate bucket for Navigator (Figure 1) and the license lamp applique for Expedition (Figure 2). The Mylar tape will act as a friction barrier between the paint surface and the trim components. 3. Make sure that the backside of the trim pieces listed in Step 2 are clean of any contaminates. This can be done by wiping the surface with a 50% solution of isopropyl alcohol and water. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 07-2-9 > Feb > 07 > Body - Paint Bubbles Around Liftgate Trim > Page 10188 4. Apply the Mylar tape to the backside edge of the trim component. It may be necessary to trim the tape after its been applied for a clean fit. 5. After applying the Mylar tape, follow installation procedure for each part as listed in the appropriate Workshop Manual, Section 501. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 070209A 2003-2006 Expedition: 1.3 Hrs. Install Mylar Tape To The Backside Edge Of The License Plate Applique, Include Time To Detrim (Do Not Use With P42D) 070209B 2003-2006 Navigator: 1.1 Hrs. Install Mylar Tape To The Backside Edge Of The License Plate Bucket, Include Time To Detrim (Do Not Use With P42D) 070209C 2003-2006 Expedition: 2.4 Hrs. Additional Time To Paint Liftgate. To Be Used With Operation A In This TSB (Includes Time For P101 Basic Paint) (Do Not Use With P42) 070209C 2003-2006 Navigator: 2.2 Hrs. Additional Time To Paint Liftgate. To Be Used With Operation B In This TSB (Includes Time For P101 Basic Paint) (Do Not Use With P42) DEALER CODING CONDITION BASIC PART NO. CODE 78404C42 D7 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 10189 Paint: By Symptom Technical Service Bulletin # 07-2-9 Date: 070205 Body - Paint Bubbles Around Liftgate Trim TSB 07-2-9 02/05/07 PAINT BUBBLES AROUND LIFTGATE TRIM FORD: 2003-2006 Expedition LINCOLN: 2003-2006 Navigator ISSUE Some 2003-2006 Expedition and Navigator vehicles may experience paint bubbling or lifting around the trim area on the liftgate. This can occur when the trim part moves on the paint surface because of climate temp changes and/or owner operation. Overtime these trim parts can rub through the paint surface and cause corrosion to start developing between the aluminum gate and paint. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Paint resurfacing will be necessary to correct the paint bubbling concern. 2. Add Mylar tape to the backside edge of the following liftgate trim parts, the license plate bucket for Navigator (Figure 1) and the license lamp applique for Expedition (Figure 2). The Mylar tape will act as a friction barrier between the paint surface and the trim components. 3. Make sure that the backside of the trim pieces listed in Step 2 are clean of any contaminates. This can be done by wiping the surface with a 50% Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 10190 solution of isopropyl alcohol and water. 4. Apply the Mylar tape to the backside edge of the trim component. It may be necessary to trim the tape after its been applied for a clean fit. 5. After applying the Mylar tape, follow installation procedure for each part as listed in the appropriate Workshop Manual, Section 501. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 070209A 2003-2006 Expedition: 1.3 Hrs. Install Mylar Tape To The Backside Edge Of The License Plate Applique, Include Time To Detrim (Do Not Use With P42D) 070209B 2003-2006 Navigator: 1.1 Hrs. Install Mylar Tape To The Backside Edge Of The License Plate Bucket, Include Time To Detrim (Do Not Use With P42D) 070209C 2003-2006 Expedition: 2.4 Hrs. Additional Time To Paint Liftgate. To Be Used With Operation A In This TSB (Includes Time For P101 Basic Paint) (Do Not Use With P42) 070209C 2003-2006 Navigator: 2.2 Hrs. Additional Time To Paint Liftgate. To Be Used With Operation B In This TSB (Includes Time For P101 Basic Paint) (Do Not Use With P42) DEALER CODING CONDITION BASIC PART NO. CODE 78404C42 D7 Disclaimer Technical Service Bulletin # 07-2-9 Date: 070205 Body - Paint Bubbles Around Liftgate Trim TSB 07-2-9 02/05/07 PAINT BUBBLES AROUND LIFTGATE TRIM Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 10191 FORD: 2003-2006 Expedition LINCOLN: 2003-2006 Navigator ISSUE Some 2003-2006 Expedition and Navigator vehicles may experience paint bubbling or lifting around the trim area on the liftgate. This can occur when the trim part moves on the paint surface because of climate temp changes and/or owner operation. Overtime these trim parts can rub through the paint surface and cause corrosion to start developing between the aluminum gate and paint. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Paint resurfacing will be necessary to correct the paint bubbling concern. 2. Add Mylar tape to the backside edge of the following liftgate trim parts, the license plate bucket for Navigator (Figure 1) and the license lamp applique for Expedition (Figure 2). The Mylar tape will act as a friction barrier between the paint surface and the trim components. 3. Make sure that the backside of the trim pieces listed in Step 2 are clean of any contaminates. This can be done by wiping the surface with a 50% solution of isopropyl alcohol and water. 4. Apply the Mylar tape to the backside edge of the trim component. It may be necessary to trim the tape after its been applied for a clean fit. 5. After applying the Mylar tape, follow installation procedure for each part as listed in the appropriate Workshop Manual, Section 501. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 10192 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 070209A 2003-2006 Expedition: 1.3 Hrs. Install Mylar Tape To The Backside Edge Of The License Plate Applique, Include Time To Detrim (Do Not Use With P42D) 070209B 2003-2006 Navigator: 1.1 Hrs. Install Mylar Tape To The Backside Edge Of The License Plate Bucket, Include Time To Detrim (Do Not Use With P42D) 070209C 2003-2006 Expedition: 2.4 Hrs. Additional Time To Paint Liftgate. To Be Used With Operation A In This TSB (Includes Time For P101 Basic Paint) (Do Not Use With P42) 070209C 2003-2006 Navigator: 2.2 Hrs. Additional Time To Paint Liftgate. To Be Used With Operation B In This TSB (Includes Time For P101 Basic Paint) (Do Not Use With P42) DEALER CODING CONDITION BASIC PART NO. CODE 78404C42 D7 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes Paint: Application and ID Paint Codes PAINT CODES Vehicle Certification Label Exterior Paint Code Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 10195 Exterior Paint Code Paint codes may be listed as a 2-part code. The first set of characters listed indicate the vehicle primary body color. The second set of characters listed (if applicable) indicate a 2-tone or accent body color. All colors are base coat/clear coat. DV - Light Tundra/Titanium Green - G2 - Redfire - G3 - Pueblo Gold - G4 - Cashmir (tri-coat) - HJ - Pewter Metallic - JP - Silver Birch Metallic - LD - Medium Wedgewood Blue - T5 - Dark Copper - T7 - Charcoal Beige - UA - Ebony - YZ - Oxford White Interior Trim Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 10196 Interior Trim Interior trim codes are listed as a 2-part code. The first character identifies the trim type. The second character identifies the interior trim color. Trim Type 1 - Milled Pebble/Toscana leather captain's chairs - 1 - Milled Pebble/Imola leather captain's chairs - 1 - Aniline cloth captain's chairs - 2 - Milled Pebble/Imola low-back bucket seats - F - Port cloth captain's chairs - K - Milled Pebble/Imola leather captain's chairs - M - Cloth 60/40 front (split bench) Interior Trim Color C - Camel Tan - D - Dove Gray - E - Medium Flint - H - Medium Parchment - W - Charcoal Black Tape/Paint Stripe Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 10197 Tape/Paint Stripe Tape and paint stripe codes do not app1y. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 10198 Paint: Application and ID Paint Code Sticker Location PAINT CODE STICKER LOCATION Vehicle Certification (VC) Label Locator Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 10199 Paint: Application and ID Paint Code Information Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 10200 Paint: Application and ID DSO Fleet Color Codes Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 10201 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 10202 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations View 151-26 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 10207 Memory Positioning Module: Diagrams C341a C341b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 10208 C341c C341d Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Diagrams > Third Row Folding Seat Relay, Left C4183 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Diagrams > Third Row Folding Seat Relay, Left > Page 10214 C4184 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left Power Seat Relay: Testing and Inspection Third Row Folding Seat Relay, Left Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 10217 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 10218 Power Seat Relay: Testing and Inspection Third Row Folding Seat Relay, Right Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 10219 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Locations View 151-19 (Left Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Locations > Page 10223 Power Trunk / Liftgate Control Module: Diagrams C4174a C4174b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Locations > Page 10224 C4174c C4174d Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Locations > Page 10225 Power Trunk / Liftgate Control Module: Service and Repair POWER LIFTGATE MODULE Removal and Installation NOTE: Prior to removal of the power liftgate module, it is necessary to upload module configuration information to a diagnostic tool. This information needs to be downloaded into the new power liftgate module once installed. 1. Remove the rear quarter trim panel. 2. Remove the power liftgate module. 1 Disconnect the electrical connectors. 2 Remove the nut. To install, tighten to 11 Nm (8 lb-ft). 3. NOTE: Once the new power liftgate module is installed, it is necessary to download the module configuration information from the diagnostic tool into the new power liftgate module. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D Technical Service Bulletin # 06-13-6 Date: 060710 A/C - Climate Controlled Seats DTC B272C or B272D TSB 06-13-6 07/10/06 DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-14-10 to update the Service Procedure. ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs) B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various sources, making them difficult to diagnose. ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT061306 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14C724 42 Disclaimer Section 1 SECTION 1 1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General Procedures; Supplemental Restraint System Depowering and Repowering. 2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a, C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10234 3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS fails when activated in the heat mode. a. If the time to failure is 5 seconds or less then, proceed to Section 2. b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section 3. c. If the time to failure is 40 seconds or greater, then, proceed to Section 4. NOTE THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4 THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED. THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK. Section 2 SECTION 2 (Seat Shuts Off In Less Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system. a. If there is an over-temp DTC present then go to Step 3. b. If no over-temp DTC is present then go to Step 6. 3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go to Step 4. b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11. c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair as needed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10235 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger cushion) Figure 1.) a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM. b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms? (1) If no, then replace TED. (2) If yes, go to Step 5. 5. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then go to Step 6. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to Step 12. b. If not then proceed to Step 7. 7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then proceed to Step 8. b. If no, then go to Step 9 in Section 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10236 8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) a. If plugged in, then proceed to Step 9. b. If not plugged in, then correct and proceed to Step 12. 9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM). (Figure 2) a. If it is open, then proceed to Step 10. b. If it is not open, then proceed to Step 11. 10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the harnesses). a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step 12. b. If the wire harnesses are good, then proceed to Step 11. 11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms (proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room temperature)? a. No, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. Yes, then replace the DCCSM and proceed to Step 12. 12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to customer. Section 3 SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B). a. If there is an over-temp DTC present, then continue to Step 3. b. If there is no over-temp DTC present, then continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10237 c. If CCS is now operable, then repower the SRS and return vehicle to customer. 3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If readings are hotter than room temperature, go to Step 4. b. If TED temperatures between Back and Cushion are 100 different, go to Step 12. c. If reading correctly then, proceed to Step 5. 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion). (Figure 1) a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on. (1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground. (2) If yes, fix the wiring, if no replace the DCCSM. b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms? (1) If yes, go to Step 5. (2) If no, then replace TED. (Figure 2) 5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, go to Step 6. b. If no, go to Step 7. 6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to Pin 2. a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM, otherwise replace the harness. Verify system now functions and return vehicle to customer. b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system now functions and return vehicle to customer. 7. Cycle ignition and enter into high cool mode. Does failure still occur? a. If no, proceed to Step 8. b. If yes, proceed to Step 13. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10238 8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED connector. NOTE DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE a. If voltage is not getting to the suspect TED, proceed to Step 9. b. If voltage is getting to the suspect TED, replace TED. 9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the module. (Figure 3) ^ Driver Cushion - Pin 9 ^ Driver Backrest - Pin 8 ^ Passenger Cushion - Pin 11 ^ Passenger Backrest - Pin 22 a. If no voltage is coming out of the module, then replace the module and continue to Step 13. b. If the correct voltage is coming out of the module, then continue to Step 10. 10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found, then continue to Step 11. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10239 11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2 volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5) 12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms (proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room temperature)? a. If no, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. If yes, then proceed to Step 13. 13. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1. b. Time to failure is not different than before, then continue to Step 14. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10240 14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7) a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10241 b. If there are no kinks or obstructions of the ducting then, continue to Step 16. 15. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 16. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10242 16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been obstructed or damaged or bunched in the cushion blocking air flow from the TED. a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 17. b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then replace the TED and continue to Step 17. 17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer. Section 4 SECTION 4 (Seat Shuts Off After More Than 40 Seconds) 1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected seat when a heating cycle is initiated. a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2. b. If the TEDs both increase temperature, then proceed to Step 3. 2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED that does not increase temperature from Step 1. a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed to Step 3. b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED, verify the fix and proceed to Step 6. 3. Check for any kinks or obstructions of the ducting from the fan to the TED. a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible otherwise replace the ducting and continue to Step 4. b. If there are no kinks or obstructions of the ducting, then continue to Step 5. 4. If CCS continues to be inoperable with DTC B272C/D code and Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10243 a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 5. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion alignment is incorrect. a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6. b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6. c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 6. d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a climate control seat, then replace the TED and continue to Step 6. 6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer. Section 5 SECTION 5 (Spread Terminal Fix Procedure) 1. Position the front passenger seat fully rearward and up. 2. Pull out and remove the seat track front cover. 3. Disconnect Connector C3265B 24-pin gray. (Figure 3). 4. Remove the red secondary wedge inside the connector. 5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3). NOTE DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG CAVITY. 6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the terminal) and bend the spring into the proper position (Figure 10). 7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the connector. 8. Reconnect C3265B to the dual climate control seat module. 9. Reinstall the seat track front cover. 10. Repower the SRS. Refer to WSM, Section 501-20B. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10244 11. Verify the climate control seat function, and recheck DTCs. 12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D Technical Service Bulletin # 06-13-6 Date: 060710 A/C - Climate Controlled Seats DTC B272C or B272D TSB 06-13-6 07/10/06 DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-14-10 to update the Service Procedure. ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs) B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various sources, making them difficult to diagnose. ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT061306 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14C724 42 Disclaimer Section 1 SECTION 1 1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General Procedures; Supplemental Restraint System Depowering and Repowering. 2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a, C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10250 3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS fails when activated in the heat mode. a. If the time to failure is 5 seconds or less then, proceed to Section 2. b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section 3. c. If the time to failure is 40 seconds or greater, then, proceed to Section 4. NOTE THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4 THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED. THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK. Section 2 SECTION 2 (Seat Shuts Off In Less Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system. a. If there is an over-temp DTC present then go to Step 3. b. If no over-temp DTC is present then go to Step 6. 3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go to Step 4. b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11. c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair as needed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10251 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger cushion) Figure 1.) a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM. b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms? (1) If no, then replace TED. (2) If yes, go to Step 5. 5. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then go to Step 6. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to Step 12. b. If not then proceed to Step 7. 7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then proceed to Step 8. b. If no, then go to Step 9 in Section 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10252 8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) a. If plugged in, then proceed to Step 9. b. If not plugged in, then correct and proceed to Step 12. 9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM). (Figure 2) a. If it is open, then proceed to Step 10. b. If it is not open, then proceed to Step 11. 10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the harnesses). a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step 12. b. If the wire harnesses are good, then proceed to Step 11. 11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms (proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room temperature)? a. No, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. Yes, then replace the DCCSM and proceed to Step 12. 12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to customer. Section 3 SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B). a. If there is an over-temp DTC present, then continue to Step 3. b. If there is no over-temp DTC present, then continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10253 c. If CCS is now operable, then repower the SRS and return vehicle to customer. 3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If readings are hotter than room temperature, go to Step 4. b. If TED temperatures between Back and Cushion are 100 different, go to Step 12. c. If reading correctly then, proceed to Step 5. 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion). (Figure 1) a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on. (1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground. (2) If yes, fix the wiring, if no replace the DCCSM. b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms? (1) If yes, go to Step 5. (2) If no, then replace TED. (Figure 2) 5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, go to Step 6. b. If no, go to Step 7. 6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to Pin 2. a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM, otherwise replace the harness. Verify system now functions and return vehicle to customer. b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system now functions and return vehicle to customer. 7. Cycle ignition and enter into high cool mode. Does failure still occur? a. If no, proceed to Step 8. b. If yes, proceed to Step 13. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10254 8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED connector. NOTE DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE a. If voltage is not getting to the suspect TED, proceed to Step 9. b. If voltage is getting to the suspect TED, replace TED. 9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the module. (Figure 3) ^ Driver Cushion - Pin 9 ^ Driver Backrest - Pin 8 ^ Passenger Cushion - Pin 11 ^ Passenger Backrest - Pin 22 a. If no voltage is coming out of the module, then replace the module and continue to Step 13. b. If the correct voltage is coming out of the module, then continue to Step 10. 10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found, then continue to Step 11. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10255 11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2 volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5) 12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms (proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room temperature)? a. If no, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. If yes, then proceed to Step 13. 13. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1. b. Time to failure is not different than before, then continue to Step 14. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10256 14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7) a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10257 b. If there are no kinks or obstructions of the ducting then, continue to Step 16. 15. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 16. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10258 16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been obstructed or damaged or bunched in the cushion blocking air flow from the TED. a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 17. b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then replace the TED and continue to Step 17. 17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer. Section 4 SECTION 4 (Seat Shuts Off After More Than 40 Seconds) 1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected seat when a heating cycle is initiated. a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2. b. If the TEDs both increase temperature, then proceed to Step 3. 2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED that does not increase temperature from Step 1. a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed to Step 3. b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED, verify the fix and proceed to Step 6. 3. Check for any kinks or obstructions of the ducting from the fan to the TED. a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible otherwise replace the ducting and continue to Step 4. b. If there are no kinks or obstructions of the ducting, then continue to Step 5. 4. If CCS continues to be inoperable with DTC B272C/D code and Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10259 a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 5. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion alignment is incorrect. a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6. b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6. c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 6. d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a climate control seat, then replace the TED and continue to Step 6. 6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer. Section 5 SECTION 5 (Spread Terminal Fix Procedure) 1. Position the front passenger seat fully rearward and up. 2. Pull out and remove the seat track front cover. 3. Disconnect Connector C3265B 24-pin gray. (Figure 3). 4. Remove the red secondary wedge inside the connector. 5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3). NOTE DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG CAVITY. 6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the terminal) and bend the spring into the proper position (Figure 10). 7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the connector. 8. Reconnect C3265B to the dual climate control seat module. 9. Reinstall the seat track front cover. 10. Repower the SRS. Refer to WSM, Section 501-20B. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10260 11. Verify the climate control seat function, and recheck DTCs. 12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 10261 View 151-27 (Passenger Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 10262 Seat Heater Control Module: Diagrams C3265a Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 10263 C3265b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 10264 Seat Heater Control Module: Service and Repair CLIMATE CONTROLLED SEAT MODULE Removal and Installation WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - When installing a new climate control seat module (CCSM), it is necessary to carry out programmable module installation (PMI). 1. Before removing the dual CCSM, carry out the appropriate steps in the PMI procedure. 2. Position the front passenger seat all the way back and up. 3. Depower the SRS. 4. Pull out and remove the seat track front cover. 5. NOTE: The inset shows the dual climate control seat module (CCSM) retaining bracket. Remove the dual CCSM. 1 Pull the back of the dual CCSM away from the seat and slide it off the mounting bracket. 2 Disconnect the electrical connectors. 3 Remove the dual CCSM. 6. To install, reverse the removal procedure. 7. Repower the SRS. 8. Install the CCSM software data. Carry out the appropriate steps in the PMI procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D Technical Service Bulletin # 06-13-6 Date: 060710 A/C - Climate Controlled Seats DTC B272C or B272D TSB 06-13-6 07/10/06 DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-14-10 to update the Service Procedure. ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs) B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various sources, making them difficult to diagnose. ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT061306 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14C724 42 Disclaimer Section 1 SECTION 1 1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General Procedures; Supplemental Restraint System Depowering and Repowering. 2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a, C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10273 3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS fails when activated in the heat mode. a. If the time to failure is 5 seconds or less then, proceed to Section 2. b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section 3. c. If the time to failure is 40 seconds or greater, then, proceed to Section 4. NOTE THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4 THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED. THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK. Section 2 SECTION 2 (Seat Shuts Off In Less Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system. a. If there is an over-temp DTC present then go to Step 3. b. If no over-temp DTC is present then go to Step 6. 3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go to Step 4. b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11. c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair as needed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10274 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger cushion) Figure 1.) a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM. b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms? (1) If no, then replace TED. (2) If yes, go to Step 5. 5. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then go to Step 6. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to Step 12. b. If not then proceed to Step 7. 7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then proceed to Step 8. b. If no, then go to Step 9 in Section 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10275 8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) a. If plugged in, then proceed to Step 9. b. If not plugged in, then correct and proceed to Step 12. 9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM). (Figure 2) a. If it is open, then proceed to Step 10. b. If it is not open, then proceed to Step 11. 10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the harnesses). a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step 12. b. If the wire harnesses are good, then proceed to Step 11. 11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms (proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room temperature)? a. No, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. Yes, then replace the DCCSM and proceed to Step 12. 12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to customer. Section 3 SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B). a. If there is an over-temp DTC present, then continue to Step 3. b. If there is no over-temp DTC present, then continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10276 c. If CCS is now operable, then repower the SRS and return vehicle to customer. 3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If readings are hotter than room temperature, go to Step 4. b. If TED temperatures between Back and Cushion are 100 different, go to Step 12. c. If reading correctly then, proceed to Step 5. 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion). (Figure 1) a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on. (1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground. (2) If yes, fix the wiring, if no replace the DCCSM. b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms? (1) If yes, go to Step 5. (2) If no, then replace TED. (Figure 2) 5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, go to Step 6. b. If no, go to Step 7. 6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to Pin 2. a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM, otherwise replace the harness. Verify system now functions and return vehicle to customer. b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system now functions and return vehicle to customer. 7. Cycle ignition and enter into high cool mode. Does failure still occur? a. If no, proceed to Step 8. b. If yes, proceed to Step 13. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10277 8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED connector. NOTE DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE a. If voltage is not getting to the suspect TED, proceed to Step 9. b. If voltage is getting to the suspect TED, replace TED. 9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the module. (Figure 3) ^ Driver Cushion - Pin 9 ^ Driver Backrest - Pin 8 ^ Passenger Cushion - Pin 11 ^ Passenger Backrest - Pin 22 a. If no voltage is coming out of the module, then replace the module and continue to Step 13. b. If the correct voltage is coming out of the module, then continue to Step 10. 10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found, then continue to Step 11. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10278 11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2 volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5) 12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms (proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room temperature)? a. If no, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. If yes, then proceed to Step 13. 13. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1. b. Time to failure is not different than before, then continue to Step 14. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10279 14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7) a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10280 b. If there are no kinks or obstructions of the ducting then, continue to Step 16. 15. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 16. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10281 16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been obstructed or damaged or bunched in the cushion blocking air flow from the TED. a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 17. b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then replace the TED and continue to Step 17. 17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer. Section 4 SECTION 4 (Seat Shuts Off After More Than 40 Seconds) 1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected seat when a heating cycle is initiated. a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2. b. If the TEDs both increase temperature, then proceed to Step 3. 2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED that does not increase temperature from Step 1. a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed to Step 3. b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED, verify the fix and proceed to Step 6. 3. Check for any kinks or obstructions of the ducting from the fan to the TED. a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible otherwise replace the ducting and continue to Step 4. b. If there are no kinks or obstructions of the ducting, then continue to Step 5. 4. If CCS continues to be inoperable with DTC B272C/D code and Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10282 a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 5. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion alignment is incorrect. a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6. b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6. c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 6. d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a climate control seat, then replace the TED and continue to Step 6. 6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer. Section 5 SECTION 5 (Spread Terminal Fix Procedure) 1. Position the front passenger seat fully rearward and up. 2. Pull out and remove the seat track front cover. 3. Disconnect Connector C3265B 24-pin gray. (Figure 3). 4. Remove the red secondary wedge inside the connector. 5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3). NOTE DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG CAVITY. 6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the terminal) and bend the spring into the proper position (Figure 10). 7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the connector. 8. Reconnect C3265B to the dual climate control seat module. 9. Reinstall the seat track front cover. 10. Repower the SRS. Refer to WSM, Section 501-20B. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10283 11. Verify the climate control seat function, and recheck DTCs. 12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-22-17 > Nov > 05 > Restraints - Cannot Disable 'Belt Minder' Chime Seat Belt Control Module: All Technical Service Bulletins Restraints - Cannot Disable 'Belt Minder' Chime TSB 05-22-17 11/14/05 INABILITY TO DISABLE THE SUPPLEMENTAL SAFETY BELT WARNING CHIME (BELTMINDER) FORD: 2006 Expedition LINCOLN: 2006 Navigator ISSUE Some 2006 Expedition/Navigator vehicles may exhibit an inability to disable the Belt Minder function following procedures listed in the Workshop Manual or the Owner Guide. The Belt Minder function operates normally, but can not be turned off (if desired by the customer). ACTION Replace the restraint control module (RCM), which includes software to disable the Belt Minder. Refer to Workshop Manual, Section 501-20B to replace the RCM. Then follow Workshop Manual, Section 413-09 or the Owner Guide procedure to disable the Belt Minder function. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052217A 2006 Expedition: Replace 1.0 Hrs. The Restraints Control Module Includes Time To Depower And Repower The Supplemental Restraints System And Disable The Beltminder (Do Not Use With 14056D, 14056D1B, 14056D1C, 14056D1XN, 14056DZR) 052217A 2006 Navigator: Replace 1.2 Hrs. The Restraints Control Module Includes Time To Depower And Repower The Supplemental Restraints System And Disable The Beltminder (Do Not Use With 14056D, 14056D1B, 14056D1C, 14056D1XN, 14056DZR) DEALER CODING CONDITION BASIC PART NO. CODE 14B321 42 OASIS CODES: 104000, 206000 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-22-17 > Nov > 05 > Restraints - Cannot Disable 'Belt Minder' Chime > Page 10289 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 05-22-17 > Nov > 05 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D Technical Service Bulletin # 06-13-6 Date: 060710 A/C - Climate Controlled Seats DTC B272C or B272D TSB 06-13-6 07/10/06 DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-14-10 to update the Service Procedure. ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs) B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various sources, making them difficult to diagnose. ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT061306 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14C724 42 Disclaimer Section 1 SECTION 1 1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General Procedures; Supplemental Restraint System Depowering and Repowering. 2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a, C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 05-22-17 > Nov > 05 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10299 3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS fails when activated in the heat mode. a. If the time to failure is 5 seconds or less then, proceed to Section 2. b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section 3. c. If the time to failure is 40 seconds or greater, then, proceed to Section 4. NOTE THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4 THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED. THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK. Section 2 SECTION 2 (Seat Shuts Off In Less Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system. a. If there is an over-temp DTC present then go to Step 3. b. If no over-temp DTC is present then go to Step 6. 3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go to Step 4. b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11. c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair as needed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 05-22-17 > Nov > 05 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10300 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger cushion) Figure 1.) a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM. b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms? (1) If no, then replace TED. (2) If yes, go to Step 5. 5. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then go to Step 6. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to Step 12. b. If not then proceed to Step 7. 7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then proceed to Step 8. b. If no, then go to Step 9 in Section 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 05-22-17 > Nov > 05 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10301 8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) a. If plugged in, then proceed to Step 9. b. If not plugged in, then correct and proceed to Step 12. 9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM). (Figure 2) a. If it is open, then proceed to Step 10. b. If it is not open, then proceed to Step 11. 10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the harnesses). a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step 12. b. If the wire harnesses are good, then proceed to Step 11. 11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms (proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room temperature)? a. No, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. Yes, then replace the DCCSM and proceed to Step 12. 12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to customer. Section 3 SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B). a. If there is an over-temp DTC present, then continue to Step 3. b. If there is no over-temp DTC present, then continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 05-22-17 > Nov > 05 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10302 c. If CCS is now operable, then repower the SRS and return vehicle to customer. 3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If readings are hotter than room temperature, go to Step 4. b. If TED temperatures between Back and Cushion are 100 different, go to Step 12. c. If reading correctly then, proceed to Step 5. 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion). (Figure 1) a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on. (1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground. (2) If yes, fix the wiring, if no replace the DCCSM. b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms? (1) If yes, go to Step 5. (2) If no, then replace TED. (Figure 2) 5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, go to Step 6. b. If no, go to Step 7. 6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to Pin 2. a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM, otherwise replace the harness. Verify system now functions and return vehicle to customer. b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system now functions and return vehicle to customer. 7. Cycle ignition and enter into high cool mode. Does failure still occur? a. If no, proceed to Step 8. b. If yes, proceed to Step 13. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 05-22-17 > Nov > 05 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10303 8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED connector. NOTE DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE a. If voltage is not getting to the suspect TED, proceed to Step 9. b. If voltage is getting to the suspect TED, replace TED. 9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the module. (Figure 3) ^ Driver Cushion - Pin 9 ^ Driver Backrest - Pin 8 ^ Passenger Cushion - Pin 11 ^ Passenger Backrest - Pin 22 a. If no voltage is coming out of the module, then replace the module and continue to Step 13. b. If the correct voltage is coming out of the module, then continue to Step 10. 10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found, then continue to Step 11. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 05-22-17 > Nov > 05 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10304 11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2 volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5) 12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms (proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room temperature)? a. If no, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. If yes, then proceed to Step 13. 13. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1. b. Time to failure is not different than before, then continue to Step 14. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 05-22-17 > Nov > 05 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10305 14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7) a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 05-22-17 > Nov > 05 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10306 b. If there are no kinks or obstructions of the ducting then, continue to Step 16. 15. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 16. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 05-22-17 > Nov > 05 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10307 16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been obstructed or damaged or bunched in the cushion blocking air flow from the TED. a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 17. b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then replace the TED and continue to Step 17. 17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer. Section 4 SECTION 4 (Seat Shuts Off After More Than 40 Seconds) 1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected seat when a heating cycle is initiated. a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2. b. If the TEDs both increase temperature, then proceed to Step 3. 2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED that does not increase temperature from Step 1. a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed to Step 3. b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED, verify the fix and proceed to Step 6. 3. Check for any kinks or obstructions of the ducting from the fan to the TED. a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible otherwise replace the ducting and continue to Step 4. b. If there are no kinks or obstructions of the ducting, then continue to Step 5. 4. If CCS continues to be inoperable with DTC B272C/D code and Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 05-22-17 > Nov > 05 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10308 a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 5. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion alignment is incorrect. a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6. b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6. c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 6. d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a climate control seat, then replace the TED and continue to Step 6. 6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer. Section 5 SECTION 5 (Spread Terminal Fix Procedure) 1. Position the front passenger seat fully rearward and up. 2. Pull out and remove the seat track front cover. 3. Disconnect Connector C3265B 24-pin gray. (Figure 3). 4. Remove the red secondary wedge inside the connector. 5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3). NOTE DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG CAVITY. 6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the terminal) and bend the spring into the proper position (Figure 10). 7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the connector. 8. Reconnect C3265B to the dual climate control seat module. 9. Reinstall the seat track front cover. 10. Repower the SRS. Refer to WSM, Section 501-20B. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 05-22-17 > Nov > 05 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10309 11. Verify the climate control seat function, and recheck DTCs. 12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D Technical Service Bulletin # 06-13-6 Date: 060710 A/C - Climate Controlled Seats DTC B272C or B272D TSB 06-13-6 07/10/06 DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-14-10 to update the Service Procedure. ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs) B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various sources, making them difficult to diagnose. ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT061306 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14C724 42 Disclaimer Section 1 SECTION 1 1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General Procedures; Supplemental Restraint System Depowering and Repowering. 2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a, C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10315 3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS fails when activated in the heat mode. a. If the time to failure is 5 seconds or less then, proceed to Section 2. b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section 3. c. If the time to failure is 40 seconds or greater, then, proceed to Section 4. NOTE THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4 THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED. THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK. Section 2 SECTION 2 (Seat Shuts Off In Less Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system. a. If there is an over-temp DTC present then go to Step 3. b. If no over-temp DTC is present then go to Step 6. 3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go to Step 4. b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11. c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair as needed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10316 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger cushion) Figure 1.) a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM. b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms? (1) If no, then replace TED. (2) If yes, go to Step 5. 5. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then go to Step 6. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to Step 12. b. If not then proceed to Step 7. 7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then proceed to Step 8. b. If no, then go to Step 9 in Section 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10317 8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) a. If plugged in, then proceed to Step 9. b. If not plugged in, then correct and proceed to Step 12. 9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM). (Figure 2) a. If it is open, then proceed to Step 10. b. If it is not open, then proceed to Step 11. 10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the harnesses). a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step 12. b. If the wire harnesses are good, then proceed to Step 11. 11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms (proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room temperature)? a. No, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. Yes, then replace the DCCSM and proceed to Step 12. 12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to customer. Section 3 SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B). a. If there is an over-temp DTC present, then continue to Step 3. b. If there is no over-temp DTC present, then continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10318 c. If CCS is now operable, then repower the SRS and return vehicle to customer. 3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If readings are hotter than room temperature, go to Step 4. b. If TED temperatures between Back and Cushion are 100 different, go to Step 12. c. If reading correctly then, proceed to Step 5. 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion). (Figure 1) a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on. (1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground. (2) If yes, fix the wiring, if no replace the DCCSM. b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms? (1) If yes, go to Step 5. (2) If no, then replace TED. (Figure 2) 5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, go to Step 6. b. If no, go to Step 7. 6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to Pin 2. a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM, otherwise replace the harness. Verify system now functions and return vehicle to customer. b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system now functions and return vehicle to customer. 7. Cycle ignition and enter into high cool mode. Does failure still occur? a. If no, proceed to Step 8. b. If yes, proceed to Step 13. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10319 8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED connector. NOTE DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE a. If voltage is not getting to the suspect TED, proceed to Step 9. b. If voltage is getting to the suspect TED, replace TED. 9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the module. (Figure 3) ^ Driver Cushion - Pin 9 ^ Driver Backrest - Pin 8 ^ Passenger Cushion - Pin 11 ^ Passenger Backrest - Pin 22 a. If no voltage is coming out of the module, then replace the module and continue to Step 13. b. If the correct voltage is coming out of the module, then continue to Step 10. 10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found, then continue to Step 11. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10320 11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2 volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5) 12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms (proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room temperature)? a. If no, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. If yes, then proceed to Step 13. 13. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1. b. Time to failure is not different than before, then continue to Step 14. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10321 14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7) a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10322 b. If there are no kinks or obstructions of the ducting then, continue to Step 16. 15. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 16. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10323 16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been obstructed or damaged or bunched in the cushion blocking air flow from the TED. a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 17. b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then replace the TED and continue to Step 17. 17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer. Section 4 SECTION 4 (Seat Shuts Off After More Than 40 Seconds) 1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected seat when a heating cycle is initiated. a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2. b. If the TEDs both increase temperature, then proceed to Step 3. 2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED that does not increase temperature from Step 1. a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed to Step 3. b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED, verify the fix and proceed to Step 6. 3. Check for any kinks or obstructions of the ducting from the fan to the TED. a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible otherwise replace the ducting and continue to Step 4. b. If there are no kinks or obstructions of the ducting, then continue to Step 5. 4. If CCS continues to be inoperable with DTC B272C/D code and Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10324 a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 5. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion alignment is incorrect. a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6. b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6. c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 6. d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a climate control seat, then replace the TED and continue to Step 6. 6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer. Section 5 SECTION 5 (Spread Terminal Fix Procedure) 1. Position the front passenger seat fully rearward and up. 2. Pull out and remove the seat track front cover. 3. Disconnect Connector C3265B 24-pin gray. (Figure 3). 4. Remove the red secondary wedge inside the connector. 5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3). NOTE DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG CAVITY. 6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the terminal) and bend the spring into the proper position (Figure 10). 7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the connector. 8. Reconnect C3265B to the dual climate control seat module. 9. Reinstall the seat track front cover. 10. Repower the SRS. Refer to WSM, Section 501-20B. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10325 11. Verify the climate control seat function, and recheck DTCs. 12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations View 151-23 (Roof) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 10329 C921 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations > Page 10333 C2110 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations > Page 10334 Trailer Towing Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations > Page 10335 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Roof Opening Panel - Exploded View Sunroof / Moonroof Motor: Service and Repair Roof Opening Panel - Exploded View ROOF OPENING PANEL - EXPLODED VIEW Removal And Installation 1. For additional information, refer to the procedures. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Roof Opening Panel - Exploded View > Page 10342 Sunroof / Moonroof Motor: Service and Repair Roof Opening Panel Motor Initialization ROOF OPENING PANEL MOTOR INITIALIZATION CAUTION: Be sure there are no obstructions in the path of the roof opening panel glass before attempting to initialize the roof opening panel motor. NOTE: - A new roof opening panel motor will only open and must be initialized. - The roof opening panel motor initialization procedure must be done when repairs are carried out on any part of the roof opening panel system, including: any time the roof opening panel motor has been removed from the roof opening panel assembly, a new roof opening panel motor has been installed, or when a new roof opening panel assembly has been installed. 1. Turn the ignition to the RUN position. For an existing roof opening panel motor, proceed to Step 3. 2. NOTE: If the open switch is released before initialization movements are complete, turn the ignition key to the OFF position, then back to the RUN position, and repeat this step. For a new roof opening panel motor/module: Press and hold the open switch until the roof opening panel moves past full OPEN, then back to full OPEN. Quickly release the open switch. - Press and hold the open switch. The roof opening panel glass will move to full TILT, then back to CLOSED (initialization movements). The initialization movements will start within approximately 3 seconds after the switch is pressed. When the initialization movements are complete, go to Step 4. 3. NOTE: - Some roof opening panel motor/module assemblies may have an electronically controlled comfort STOP position, which is approximately 2 in. (50 mm) from the full OPEN position. When the roof opening panel is opened on vehicles equipped with this type of motor/module, the open switch must be released when the comfort STOP position has been reached, and then pressed again to fully open the roof opening panel. - If the open switch is released before initialization movements are complete, turn the ignition key to the OFF position, then back to the RUN position, and repeat this step. For an existing roof opening panel motor/module: Press and hold the open switch until the roof opening panel glass moves to the full OPEN position. - Press and hold the open switch (for approximately 10 seconds) until the roof opening panel glass moves past full OPEN, then back to full OPEN. Quickly release the switch. - Press and hold the open switch. The roof opening panel glass will move to full TILT, then back to CLOSED (initialization movements). The initialization movements will start within approximately 3 seconds after the switch is pressed. 4. Release the open switch and test the system for normal operation by carrying out one-touch open to comfort STOP, full OPEN, close from full OPEN to full CLOSE and TILT operations. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Roof Opening Panel - Exploded View > Page 10343 Sunroof / Moonroof Motor: Service and Repair Roof Opening Panel Motor ROOF OPENING PANEL MOTOR Removal NOTE: The roof opening panel must be initialized when repairs are carried out on any part of the roof opening panel, including whenever the roof opening panel has been removed from the roof opening panel assembly, a new roof opening panel motor/module has been installed or when a new roof opening panel assembly has been installed. Refer to Roof Opening Panel Motor Initialization. 1. Remove the headliner. 2. Disconnect the roof opening panel motor electrical connector and cut the tie strap. 3. Remove the roof opening panel motor. - Remove the 3 bolts. Installation 1. Connect the roof opening panel motor electrical connector. Install a new tie wrap and trim off excess. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Roof Opening Panel - Exploded View > Page 10344 2. NOTE: When installing the roof opening panel motor/module, align the 3 attach holes before engaging the drive gear into the roof opening panel drive cable. Do not rotate the motor assembly after the drive gear is engaged with the roof opening panel drive cable. Otherwise, the cable can bind. Install the roof opening panel motor. Align the attach holes, then install the 3 bolts and tighten to 4 Nm (35 lb-in). 3. Connect the overhead console electrical connectors. 4. Initialize the roof opening panel motor/module. 5. Disconnect the overhead console electrical connectors. 6. Install the headliner. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations View 151-23 (Roof) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Page 10348 Sunroof / Moonroof Switch: Diagrams C912 C9001 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Page 10349 Sunroof / Moonroof Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Page 10350 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair Sunroof / Moonroof Track: Service and Repair ROOF OPENING PANEL REAR TROUGH GUIDE Removal and Installation NOTE: The roof opening panel must be initialized when repairs are carried out on any part of the roof opening panel, including: whenever the roof opening panel has been removed from the roof opening panel assembly, a new roof opening panel motor/module has been installed or when a new roof opening panel assembly has been installed. 1. Remove the roof opening panel. 2. Remove the 2 trough guide retaining screws. - To install, tighten to 1 Nm (9 lb-in). 3. Remove the trough from the trough guide assembly. 4. Disconnect the trough guide rods from the lifter arm assemblies. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Page 10354 5. Slide the trough guide back to the slot (approximately 15 mm (0.6 in)) cut in track. 6. Carefully twist trough guide through the slot in the track to remove. 7. Inspect the trough guide assembly for damage. If damage is found, inspect the track for broken pieces and remove them. 8. To install, reverse the removal procedure. 9. Adjust roof opening panel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Roof Opening Panel - Exploded View Sunroof / Moonroof Windguard: Service and Repair Roof Opening Panel - Exploded View ROOF OPENING PANEL - EXPLODED VIEW Removal And Installation 1. For additional information, refer to the procedures. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Roof Opening Panel - Exploded View > Page 10359 Sunroof / Moonroof Windguard: Service and Repair Air Deflector AIR DEFLECTOR Removal and Installation 1. Open the roof opening panel. 2. NOTE: RH side shown, LH similar. Remove the 2 air deflector tether screws. To install, tighten to 1 Nm (9 lb-in). 3. Raise the front of the air deflector. 4. Slide the air deflector toward the rear, then lift up to release it from the pivot shafts. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Roof Opening Panel - Exploded View Sunroof / Moonroof Frame: Service and Repair Roof Opening Panel - Exploded View ROOF OPENING PANEL - EXPLODED VIEW Removal And Installation 1. For additional information, refer to the procedures. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Roof Opening Panel - Exploded View > Page 10364 Sunroof / Moonroof Frame: Service and Repair Roof Opening Panel Frame ROOF OPENING PANEL FRAME Removal and Installation NOTE: The roof opening panel must be initialized when repairs are carried out on any part of the roof opening panel, including whenever the roof opening panel has been removed from the roof opening panel assembly, a new roof opening panel motor/module has been installed or when a new roof opening panel assembly has been installed. Refer to Roof Opening Panel Motor Initialization. 1. Remove the headliner. 2. Remove the overhead console bracket. - Remove the screws. 3. Disconnect the electrical connector and cut the tie strap. 4. Remove the roof opening panel frame. 1 Disconnect the 4 roof opening panel drain hoses. 2 Remove the 11 bolts. To install, tighten to 10 Nm (89 lb-in). 3 Remove the roof opening panel frame. 5. To install, reverse the removal procedure. If a new roof opening panel frame is being installed, transfer the existing roof opening panel motor, air deflector, rear trough, roof opening panel glass and roof opening panel shield onto the new frame assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Roof Opening Panel - Exploded View > Page 10365 - Check for correct alignment of the roof opening panel. - Initialize the roof opening panel motor. Refer to Roof Opening Panel Motor Initialization. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations View 151-23 (Roof) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations > Page 10369 C921 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair Sunroof / Moonroof Panel: Service and Repair ROOF OPENING PANEL Removal and Installation NOTE: The roof opening panel must be initialized when repairs are carried out on any part of the roof opening panel, including: whenever the roof opening panel has been removed from the roof opening panel assembly, a new roof opening panel motor/module has been installed or when a new roof opening panel assembly has been installed. 1. Position the roof opening panel in the VENT position. 2. Remove the 4 roof opening panel bolts. - To install, tighten to 4 Nm (35 lb-in). 3. Remove the roof opening panel from the outside of the vehicle by lifting up and out. 4. To install, reverse the removal procedure. - Adjust the roof opening panel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash Sunroof / Moonroof Weatherstrip: Customer Interest Body - Sunroof Water Leaks During High Pressure Car Wash TSB 08-24-8 12/08/08 WATER LEAKS - ROOF OPENING PANEL DURING HIGH PRESSURE CAR WASH FORD: 2005-2008 F-150, F-250, F-350, F-450, F-550 2005-2009 Expedition LINCOLN: 2005-2009 Navigator 2006-2008 Mark LT This article supersedes TSB 08-1-4 to update the Part List and Service procedure. ISSUE Some 2005-2009 Expedition, Navigator, 2005-2008 F-150, F-Super Duty and 2006-2008 Mark LT vehicles with factory installed roof opening panel may experience a water leak at the rear of roof opening panel during a high pressure car wash. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2005-2008 F-150 / F-Super Duty 250-550 / 2006-2008 Mark LT 1. Remove roof opening panel glass only. Refer to Work Shop Manual (WSM), Section 501-17. 2. To avoid paint damage to the roof, apply protective covering on roof finish. 3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from the trough guide assembly. 4. With rear trough removed; wipe clean the top inside of the trough with an alcohol based cleaner or equivalent. 5. Remove the adhesive tape covering from trough seal. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash > Page 10381 6. Attach seal to front of trough starting at one end of the trough. Make sure the vertical leg of seal lines up against front flange of trough. (Figures 1-3) 7. Secure seal across entire trough. Apply pressure along entire seal to ensure bonding to trough. 8. Install the rear trough onto the trough guide assembly. Install the two (2) trough guide retaining screws and torque to 9 lb-in. (1 N.m) 9. Remove protective covering. 10. Install roof opening panel following WSM, Section 501-17. 2005-2009 Expedition / Navigator 1. Remove roof opening panel glass only. Refer to WSM, Section 501-17. 2. To avoid paint damage to the roof, apply protective covering on roof finish. 3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from the trough guide assembly. 4. Install new trough and seal assembly. 5. Install the rear trough and seal assembly onto the trough guide assembly. Install the two (2) trough guide retaining screws and torque to 9 lb-in. (1 N.m) 6. Remove protective covering. 7. Install roof opening panel following WSM, Section 501-17. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash > Page 10382 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082408A 2005-2009 Expedition, 0.5 Hr. Navigator: Follow The Service Procedure To Repair The Water leak (Do Not Use With 5028A) 082408A 2005-2008 F-Super Duty, 0.6 Hr. F-150, 2005-2008 Mark LT: Follow The Service Procedure To Repair The Water leak (Do Not Use With 5028A) DEALER CODING CONDITION BASIC PART NO. CODE 78502C50 07 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash Sunroof / Moonroof Weatherstrip: All Technical Service Bulletins Body - Sunroof Water Leaks During High Pressure Car Wash TSB 08-24-8 12/08/08 WATER LEAKS - ROOF OPENING PANEL DURING HIGH PRESSURE CAR WASH FORD: 2005-2008 F-150, F-250, F-350, F-450, F-550 2005-2009 Expedition LINCOLN: 2005-2009 Navigator 2006-2008 Mark LT This article supersedes TSB 08-1-4 to update the Part List and Service procedure. ISSUE Some 2005-2009 Expedition, Navigator, 2005-2008 F-150, F-Super Duty and 2006-2008 Mark LT vehicles with factory installed roof opening panel may experience a water leak at the rear of roof opening panel during a high pressure car wash. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2005-2008 F-150 / F-Super Duty 250-550 / 2006-2008 Mark LT 1. Remove roof opening panel glass only. Refer to Work Shop Manual (WSM), Section 501-17. 2. To avoid paint damage to the roof, apply protective covering on roof finish. 3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from the trough guide assembly. 4. With rear trough removed; wipe clean the top inside of the trough with an alcohol based cleaner or equivalent. 5. Remove the adhesive tape covering from trough seal. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash > Page 10388 6. Attach seal to front of trough starting at one end of the trough. Make sure the vertical leg of seal lines up against front flange of trough. (Figures 1-3) 7. Secure seal across entire trough. Apply pressure along entire seal to ensure bonding to trough. 8. Install the rear trough onto the trough guide assembly. Install the two (2) trough guide retaining screws and torque to 9 lb-in. (1 N.m) 9. Remove protective covering. 10. Install roof opening panel following WSM, Section 501-17. 2005-2009 Expedition / Navigator 1. Remove roof opening panel glass only. Refer to WSM, Section 501-17. 2. To avoid paint damage to the roof, apply protective covering on roof finish. 3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from the trough guide assembly. 4. Install new trough and seal assembly. 5. Install the rear trough and seal assembly onto the trough guide assembly. Install the two (2) trough guide retaining screws and torque to 9 lb-in. (1 N.m) 6. Remove protective covering. 7. Install roof opening panel following WSM, Section 501-17. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash > Page 10389 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082408A 2005-2009 Expedition, 0.5 Hr. Navigator: Follow The Service Procedure To Repair The Water leak (Do Not Use With 5028A) 082408A 2005-2008 F-Super Duty, 0.6 Hr. F-150, 2005-2008 Mark LT: Follow The Service Procedure To Repair The Water leak (Do Not Use With 5028A) DEALER CODING CONDITION BASIC PART NO. CODE 78502C50 07 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Page 10390 Sunroof / Moonroof Weatherstrip: Service and Repair ROOF OPENING PANEL WEATHERSTRIP Removal NOTE: The roof opening panel must be initialized when repairs are carried out on any part of the roof opening panel, including: whenever the roof opening panel has been removed from the roof opening panel assembly, a new roof opening panel motor/module has been installed or when a new roof opening panel assembly has been installed. 1. Remove the roof opening panel. 2. Place roof opening panel, topside up, on a worktable. Take care to support the glass assembly from below to prevent damaging the mounting tabs. 3. Remove the old roof opening panel weatherstrip by pulling up on the weatherstrip. Installation 1. Place a new weatherstrip into position on the glass assembly, with the splice (seam) on the passenger side. 2. Starting with the corners, push the weatherstrip into position. Continue pushing the weatherstrip into position around the glass assembly until complete. Use a plastic or rubber hammer if necessary. 3. Install the roof opening panel. 4. Adjust the roof panel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations View 151-26 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 10396 Memory Positioning Module: Diagrams C341a C341b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 10397 C341c C341d Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations View 151-28 (Driver Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 10401 C503 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 10402 Seat Memory Switch: Testing and Inspection SWITCH - MEMORY SET Memory Set Switch Remove the memory set switch. Measure the resistance between the indicated terminals while pressing the requested switches. The resistance should be less than 5 ohms for each switch position. If the resistance is not less than 5 ohms for each switch, install a new switch; otherwise, return to the calling pinpoint test. NOTE: Refer to multimeter user's manual for testing diodes. To check the memory set switch LED, connect the positive meter lead to terminal 7 and the negative lead to terminal 1. 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, install a new switch; otherwise, return to the calling pinpoint test. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third Row Folding Seat Motor, Left View 151-19 (Left Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third Row Folding Seat Motor, Left > Page 10407 View 151-21 (Right Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third Row Folding Seat Motor, Left > Page 10408 View 151-26 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third Row Folding Seat Motor, Left > Page 10409 View 151-27 (Passenger Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third Row Folding Seat Motor, Left > Page 10410 Power Seat Motor: Locations View 151-19 (Left Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third Row Folding Seat Motor, Left > Page 10411 View 151-21 (Right Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third Row Folding Seat Motor, Left > Page 10412 View 151-26 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third Row Folding Seat Motor, Left > Page 10413 View 151-27 (Passenger Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third Row Folding Seat Motor, Left > Page 10414 View 151-27 (Passenger Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third Row Folding Seat Motor, Left > Page 10415 View 151-26 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third Row Folding Seat Motor, Left > Page 10416 View 151-26 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third Row Folding Seat Motor, Left > Page 10417 View 151-27 (Passenger Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third Row Folding Seat Motor, Left > Page 10418 View 151-26 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third Row Folding Seat Motor, Left > Page 10419 View 151-27 (Passenger Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor C332 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor > Page 10422 C3074 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor > Page 10423 C3075 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor > Page 10424 C3187 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor > Page 10425 Power Seat Motor: Diagrams C332 C3074 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor > Page 10426 C3075 C3187 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor > Page 10427 C363 C382 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor > Page 10428 C362 C3189 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor > Page 10429 C3215 C3216 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Passenger Seat Horizontal Motor > Page 10430 C4181 C4182 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Front Seat Track Motor Power Seat Motor: Service and Repair Front Seat Track Motor FRONT SEAT TRACK MOTOR Removal and Installation WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All motors 1. Position the seat to gain access to all seat track-to-floor fasteners (if possible). 2. Depower the SRS. 3. Remove the 40 percent seat. Forward/reverse motor 4. NOTE: If equipped with memory seat, disconnect the memory seat position sensor electrical connector and remove sensor from the motor. Remove the forward/reverse motor. 1 Disconnect the electrical connector. 2 Pull to release the power seat drive cables from the motor. 3 Remove the 4 screws (2 shown). 4 Remove the power seat motor. Rear height motor 5. NOTE: If equipped with memory seat, disconnect the memory seat position sensor electrical connector and remove sensor from the motor. Remove the rear height motor. Disconnect the rear height motor electrical connector. - Remove the roll pin. - Remove the bolt and nut. - Remove the rear height power seat motor. Front height motor 6. If equipped, remove the temperature controlled seat fan motor. 7. NOTE: If equipped with memory seat, disconnect the memory seat position sensor electrical connector and remove sensor from the motor. Remove the front height motor. Disconnect the front height motor electrical connector. - Remove the roll pin. - Remove the roll pin. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Front Seat Track Motor > Page 10433 - Remove the front height power seat motor. All motors 8. To install, reverse the removal procedure 9. Install the 40 percent seat. 10. Repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Front Seat Track Motor > Page 10434 Power Seat Motor: Service and Repair Front Seat Recliner Motor FRONT SEAT RECLINER MOTOR Removal and Installation WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Position the seat to gain access to all seat track-to-floor fasteners. 2. Depower the SRS. 3. Remove the 40 percent seat. 4. Remove the lower backrest cover. 5. Remove the 2 screws and the securing strap. 6. Release the backrest trim cover hook-and-loop strip and J-clip. 7. Depress the head restraint guide tab and remove the head restraint. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Front Seat Track Motor > Page 10435 8. NOTE: The head restraint guides are not interchangeable. Note location for installation. Reach up into backrest and squeeze the head restraint guide ends together to release and pull the 2 head restraint guides out. 9. CAUTION: Use care when separating the seat backrest trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat backrest foam. Invert the backrest trim cover and remove. 10. CAUTION: Use care when removing the backrest foam pad from the frame. The foam pad has hook and loop fasteners holding the thermo-electric device to the backrest foam pad. Separate the backrest foam pad from the backrest thermo-electric device and remove the backrest foam pad. 11. Remove the backrest pivot rod retainer on the end of the backrest pivot rod. 12. Remove the backrest pivot rod cover and slide the backrest pivot rod out from the power recline motor. 13. Disconnect the electrical connector, remove the bolt and the power recline motor. 14. To install, reverse the removal procedure. 15. Install the 40 percent seat. 16. Repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Front Seat Track Motor > Page 10436 Power Seat Motor: Service and Repair Lumbar Motor LUMBAR MOTOR Removal and Installation WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Position the seat to gain access to all seat track-to-floor fasteners. 2. Depower the SRS. 3. Remove the 40 percent seat. 4. Remove lower backrest cover. 5. Remove the 2 screws and the securing strap. 6. Release the backrest trim cover hook-and-loop strip and J-clip. 7. Depress the head restraint guide tab and remove the head restraint. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Front Seat Track Motor > Page 10437 8. NOTE: The head restraint guides are not interchangeable. Note location for Installation. Reach up into backrest and squeeze the head restraint guide ends together to release and pull the 2 head restraint guides out. 9. CAUTION: Use care when separating the seat backrest trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat backrest foam. Invert the backrest trim cover and remove. 10. CAUTION: Use care when removing the backrest foam pad from the frame. The foam pad has hook and loop fasteners holding the thermo-electric device to the backrest foam pad. Separate the backrest foam pad from the thermo-electric device and remove the backrest foam pad. 11. Remove the 2 inboard backrest support bracket screws and the inboard backrest support bracket. 12. Remove the lumbar motor cable from the lumbar support. 1 Flex the lumbar support. 2 Separate the lumbar support adjusting cable from the positioning spring. 3 Unhook the lumbar support adjusting cable from the lumbar support. 13. Remove the staples and open dampening bag. 14. Remove the power lumbar support motor. - Disconnect the power lumbar motor electrical connector. - Remove the 2 screws. - Remove the power lumbar motor. 15. To install, reverse the removal procedure. 16. Install the 40 percent seat. 17. Repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Front Seat Track Motor > Page 10438 Power Seat Motor: Service and Repair Power-Fold Seat Motor POWER-FOLD SEAT MOTOR Removal and Installation NOTE: A cable assembly service kit is available. All vehicles 1. Remove the affected third row seat. 2. Lift the cushion up, remove the inboard slide bracket cover-to-inboard slide bracket screw and slide the cover up and out of the way. - To install, tighten to 3 Nm (27 lb-ft). 3. Remove the safety belt anchor bolt. - To install, tighten to 40 Nm (30 lb-ft). 4. Remove the inboard slide bracket-to-inboard latch nut and separate the inboard slide bracket from the inboard latch. - To install, tighten to 15 Nm (11 lb-ft). 5. Remove the inboard latch-to-backrest frame bolts and remove the inboard latch. - To install, tighten to 55 Nm (41 lb-ft). Cable repair 6. NOTE: The motor should only need to be removed when installing a cable assembly service kit. If necessary, grind off the bottom of the rivets or drill and punch out the rivets. Remove the power-fold seat motor. All vehicles 7. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor View 151-26 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor > Page 10443 View 151-35 (Chassis, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor > Page 10444 View 151-36 (Chassis, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor > Page 10445 View 151-26 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor > Page 10446 View 151-26 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor C372 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 10449 C383 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 10450 C373 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 10451 C1151 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 10452 Power Seat Motor Position Sensor: Diagrams C372 C383 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 10453 C373 C1151 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 10454 C1153 C4084 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 10455 C3244 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Diagrams > Third Row Folding Seat Relay, Left C4183 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Diagrams > Third Row Folding Seat Relay, Left > Page 10461 C4184 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left Power Seat Relay: Testing and Inspection Third Row Folding Seat Relay, Left Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 10464 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 10465 Power Seat Relay: Testing and Inspection Third Row Folding Seat Relay, Right Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 10466 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left/Right View 151-21 (Right Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left/Right > Page 10471 View 151-26 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left/Right > Page 10472 View 151-27 (Passenger Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Left Power Seat Switch: Diagrams Left C352 C3016 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Left > Page 10475 Power Seat Switch: Diagrams Right C355 C3026 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Left > Page 10476 C4179 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Left > Page 10477 C4180 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat Power Seat Switch: Testing and Inspection Power Seat Switch, Left-6-Way Power Seat Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10480 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10481 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10482 Power Seat Switch: Testing and Inspection Power Seat Switch, Left-8-Way Power Seat Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10483 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10484 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10485 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10486 Power Seat Switch: Testing and Inspection Power Seat Switch, Right-6-Way Power Seat Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10487 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10488 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10489 Power Seat Switch: Testing and Inspection Power Seat Switch, Right-8-Way Power Seat Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10490 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10491 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10492 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10493 Power Seat Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10494 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10495 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10496 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10497 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10498 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10499 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10500 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10501 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10502 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10503 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10504 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10505 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10506 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10507 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10508 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10509 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10510 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch - 8-Way Power Seat Switch: Service and Repair Seat Control Switch - 8-Way SEAT CONTROL SWITCH - 8-WAY Removal and Installation WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Driver side shown, passenger side similar. 1. Position the seat to gain access to all seat track-to-floor fasteners. 2. Depower the SRS. 3. Remove the 40 percent seat. 4. Pry and remove the seat control switch and power recline knobs. 5. Access and remove the cushion side shield front screw. 6. Pull out from the bottom and rear side of the cushion side shield to release the 3 retainer clips. 7. Disconnect the power lumbar and seat control switch electrical connectors and remove the cushion side shield. 8. Remove the 3 screws and remove the 8-way seat control switch. 9. To install, reverse the removal procedure. 10. Install the 40 percent seat. 11. Repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch - 8-Way > Page 10513 Power Seat Switch: Service and Repair Seat Control Switch - 6-Way SEAT CONTROL SWITCH - 6-WAY Removal and Installation WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Driver seat is shown, passenger is similar. 1. Position the seat to gain access to all seat track-to-floor fasteners. 2. Depower the SRS. 3. Remove the 40 percent seat. 4. From under the seat, disconnect the 6-way power seat switch electrical connector. 5. Remove the recliner handle screw cover, screw and recliner handle. 6. CAUTION: Use care when removing the lumbar knob. Using both hands, pull with even pressure on both sides of the knob to remove. Pull out to remove the manual lumbar knob. 7. Remove the cushion side shield screw from under the manual lumbar knob. 8. CAUTION: Use care not to scratch the side shield when removing the power seat knob. Pry the seat control switch knob off. 9. Access and remove the front cushion side shield screw. 10. Pull to release the center and rear retainers and remove the cushion side shield. 11. Remove the 2 seat control switch screws and remove the 6-way seat control switch from the cushion side shield. 12. To install, reverse the removal procedure. 13. Install the 40 percent seat. 14. Repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch - 8-Way > Page 10514 Power Seat Switch: Service and Repair Seat Control Switch - Third Row SEAT CONTROL SWITCH - THIRD ROW Removal and Installation 1. Partially remove the RH quarter trim panel for access to the third row power seat switch(es.). 2. Remove the one-way push nuts on the back side of the power seat switch bezel. 3. Disconnect the RH and LH third row seat control switch electrical connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch - 8-Way > Page 10515 4. Release the 4 locking tabs (2 shown) on the affected switch, and remove the switch. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion - 40 Percent Seat Cushion: Service and Repair Front Seat Cushion - 40 Percent FRONT SEAT CUSHION - 40 PERCENT Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion - 40 Percent > Page 10520 Part 2 Disassembly and Assembly WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All seats 1. Position the seat to gain access to all seat track-to-floor fasteners. 2. Depower the SRS. 3. Remove the 40 percent seat. 4. Remove the side shield. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion - 40 Percent > Page 10521 5. Release the J-clips on the pivot covers (inboard shown, outboard similar). 6. Release the cushion trim cover J-clips. 7. CAUTION: Use care when separating the cushion trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the cushion foam pad. Remove the cushion trim cover. 8. Remove the cushion foam pad. Power seats 9. Remove the power seat motors. 10. Remove the power seat tracks. Manual seats 11. Remove the manual seat track. Manual lumbar seats 12. Remove the 2 screws and the manual lumbar actuator. 13. NOTE: The lumbar support assembly must be fully relaxed. Separate the manual lumbar actuator from the adjuster cable. Driver memory seats Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion - 40 Percent > Page 10522 14. NOTE: The inset shows the driver seat module (DSM) retaining bracket. Remove the DSM. 1 Pull the back of the DSM away from the seat and slide it off the mounting bracket. 2 Disconnect the electrical connectors. 3 Remove the DSM. Climate controlled seats 15. Remove the seat fan motor. 16. Remove the climate controlled seat module. 17. Remove the seat cushion thermo-electric device. 18. Remove the cushion supply duct. 19. Unclip and remove the TED mounting bezel. All seats 20. To assemble, reverse the disassembly procedure. 21. Install the 40 percent seat. 22. Repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion - 40 Percent > Page 10523 Seat Cushion: Service and Repair Front Seat Cushion - 60 Percent FRONT SEAT CUSHION - 60 PERCENT Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion - 40 Percent > Page 10524 Part 2 Disassembly WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion - 40 Percent > Page 10525 NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Position the seat to gain access to all seat track-to-floor fasteners. 2. Depower the SRS. 3. Remove the 60 percent seat. 4. Remove the 60 percent seat backrest. 5. Remove the armrest bracket inner cover. 6. Remove the 2 screws and the armrest bracket outer cover. 7. Release the cushion trim cover J-clips. 8. Remove the 2 bolts and the backrest recliner. - To install, tighten to 50 Nm (37 lb-ft). 9. Remove the 2 bolts and the armrest bracket. - To install, tighten to 50 Nm (37 lb-ft). 10. Remove the seat track. 11. CAUTION: Use care when separating the cushion trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the cushion foam pad. Invert the cushion trim cover and remove from the cushion foam pad. 12. Remove the cushion foam pad from the cushion frame. 13. To assemble, reverse the disassembly procedure. 14. Install the 60 percent seat backrest. 15. Install the 60 percent seat. 16. Repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion - 40 Percent > Page 10526 Seat Cushion: Service and Repair Rear Seat Cushion - Second Row, 40 Percent REAR SEAT CUSHION - SECOND ROW, 40 PERCENT Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion - 40 Percent > Page 10527 Part 2 Disassembly and Assembly 1. Remove the 40 percent seat. 2. Remove the 40 percent seat backrest. 3. Unsnap the pull strap retainer. 4. Release the 4 cushion trim cover J-clips. 5. Remove the cushion trim cover and cushion foam pad from the cushion frame. 6. CAUTION: Use care when separating the cushion trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the cushion foam pad. Remove the cushion trim cover from the cushion foam pad. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion - 40 Percent > Page 10528 7. Remove the 3 pin-type retainers from the seat bottom cover (2 shown). 8. Release the 2 J-clips for the bottom cover. 9. Remove the 4 pin-type retainers from the sides of bottom cover (2 shown). 10. Remove the bottom cover. 11. Remove the bolt and the safety belt buckle. - To aid installation, note the location of locating tab. To install, tighten to 40 Nm (30 lb-ft). 12. To assemble, reverse the disassembly procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion - 40 Percent > Page 10529 Seat Cushion: Service and Repair Rear Seat Cushion - Second Row, 20 Percent REAR SEAT CUSHION - SECOND ROW, 20 PERCENT Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion - 40 Percent > Page 10530 Part 2 Disassembly and Assembly 1. Remove the 20 percent seat. 2. Remove the 20 percent seat backrest. 3. Release the cushion trim cover front J-clip. 4. Remove the 2 riser-to-cushion frame bolts. - To install, tighten to 30 Nm (22 lb-ft). 5. Release the remaining cushion trim cover J-clips. 6. Remove the cushion frame from the cushion foam pad. 7. CAUTION: Use care when separating the seat cushion trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat cushion foam. Remove the seat cushion cover from the foam pad. 8. To assemble, reverse the disassembly procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion - 40 Percent > Page 10531 Seat Cushion: Service and Repair Front Seat Cushion - 40 Percent FRONT SEAT CUSHION - 40 PERCENT Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion - 40 Percent > Page 10532 Part 2 Disassembly and Assembly WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All seats 1. Position the seat to gain access to all seat track-to-floor fasteners. 2. Depower the SRS. 3. Remove the 40 percent seat. 4. Remove the side shield. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion - 40 Percent > Page 10533 5. Release the J-clips on the pivot covers (inboard shown, outboard similar). 6. Release the cushion trim cover J-clips. 7. CAUTION: Use care when separating the cushion trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the cushion foam pad. Remove the cushion trim cover. 8. Remove the cushion foam pad. Power seats 9. Remove the power seat motors. 10. Remove the power seat tracks. Manual seats 11. Remove the manual seat track. Manual lumbar seats 12. Remove the 2 screws and the manual lumbar actuator. 13. NOTE: The lumbar support assembly must be fully relaxed. Separate the manual lumbar actuator from the adjuster cable. Driver memory seats Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion - 40 Percent > Page 10534 14. NOTE: The inset shows the driver seat module (DSM) retaining bracket. Remove the DSM. 1 Pull the back of the DSM away from the seat and slide it off the mounting bracket. 2 Disconnect the electrical connectors. 3 Remove the DSM. Climate controlled seats 15. Remove the seat fan motor. 16. Remove the climate controlled seat module. 17. Remove the seat cushion thermo-electric device. 18. Remove the cushion supply duct. 19. Unclip and remove the TED mounting bezel. All seats 20. To assemble, reverse the disassembly procedure. 21. Install the 40 percent seat. 22. Repower the SRS. Front Seat Cushion - 60 Percent FRONT SEAT CUSHION - 60 PERCENT Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion - 40 Percent > Page 10535 Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion - 40 Percent > Page 10536 Part 2 Disassembly WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion - 40 Percent > Page 10537 NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Position the seat to gain access to all seat track-to-floor fasteners. 2. Depower the SRS. 3. Remove the 60 percent seat. 4. Remove the 60 percent seat backrest. 5. Remove the armrest bracket inner cover. 6. Remove the 2 screws and the armrest bracket outer cover. 7. Release the cushion trim cover J-clips. 8. Remove the 2 bolts and the backrest recliner. - To install, tighten to 50 Nm (37 lb-ft). 9. Remove the 2 bolts and the armrest bracket. - To install, tighten to 50 Nm (37 lb-ft). 10. Remove the seat track. 11. CAUTION: Use care when separating the cushion trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the cushion foam pad. Invert the cushion trim cover and remove from the cushion foam pad. 12. Remove the cushion foam pad from the cushion frame. 13. To assemble, reverse the disassembly procedure. 14. Install the 60 percent seat backrest. 15. Install the 60 percent seat. 16. Repower the SRS. Rear Seat Cushion - Second Row, 40 Percent REAR SEAT CUSHION - SECOND ROW, 40 PERCENT Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion - 40 Percent > Page 10538 Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion - 40 Percent > Page 10539 Part 2 Disassembly and Assembly 1. Remove the 40 percent seat. 2. Remove the 40 percent seat backrest. 3. Unsnap the pull strap retainer. 4. Release the 4 cushion trim cover J-clips. 5. Remove the cushion trim cover and cushion foam pad from the cushion frame. 6. CAUTION: Use care when separating the cushion trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the cushion foam pad. Remove the cushion trim cover from the cushion foam pad. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion - 40 Percent > Page 10540 7. Remove the 3 pin-type retainers from the seat bottom cover (2 shown). 8. Release the 2 J-clips for the bottom cover. 9. Remove the 4 pin-type retainers from the sides of bottom cover (2 shown). 10. Remove the bottom cover. 11. Remove the bolt and the safety belt buckle. - To aid installation, note the location of locating tab. To install, tighten to 40 Nm (30 lb-ft). 12. To assemble, reverse the disassembly procedure. Rear Seat Cushion - Second Row, 20 Percent REAR SEAT CUSHION - SECOND ROW, 20 PERCENT Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion - 40 Percent > Page 10541 Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion - 40 Percent > Page 10542 Part 2 Disassembly and Assembly 1. Remove the 20 percent seat. 2. Remove the 20 percent seat backrest. 3. Release the cushion trim cover front J-clip. 4. Remove the 2 riser-to-cushion frame bolts. - To install, tighten to 30 Nm (22 lb-ft). 5. Release the remaining cushion trim cover J-clips. 6. Remove the cushion frame from the cushion foam pad. 7. CAUTION: Use care when separating the seat cushion trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat cushion foam. Remove the seat cushion cover from the foam pad. 8. To assemble, reverse the disassembly procedure. Rear Seat Cushion - Third Row, 40 Percent REAR SEAT CUSHION - THIRD ROW, 40 PERCENT Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion - 40 Percent > Page 10543 40 Perecent Cushion Disassembly and Assembly 1. Remove the third row 40 percent seat. 2. Remove the third row 40 percent seat backrest. 3. Remove the inboard and outboard slide bracket-to-cushion frame nuts and remove the slide bracket from both sides of the seat cushion. - To install, tighten to 15 Nm (11 lb-ft). 4. Remove the 2 third row seat riser-to-cushion frame bolts and the riser. - To install, tighten to 30 Nm (22 lb-ft). 5. Release the cushion trim cover J-clips and remove the cushion frame. 6. CAUTION: Use care when separating the cushion trim cover from the hook and loop strip, or the hook and loop strip can be torn from Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion - 40 Percent > Page 10544 the cushion foam pad. Remove the cushion trim cover from the cushion foam pad. 7. To assemble, reverse the disassembly procedure. Rear Seat Cushion - Third Row, 60 Percent REAR SEAT CUSHION - THIRD ROW, 60 PERCENT 60 Perecent Cushion Disassembly and Assembly 1. Remove the third row 60 percent seat. 2. Remove the third row 60 percent seat backrest. 3. Remove the inboard and outboard slide bracket-to-cushion frame nuts and remove the slide bracket from both sides of the seat cushion. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion - 40 Percent > Page 10545 - To install, tighten to 15 Nm (11 lb-ft). 4. Remove the 2 seat riser-to-cushion frame bolts and the riser. - To install, tighten to 30 Nm (22 lb-ft). 5. Release the cushion trim cover J-clips and remove the cushion frame. 6. CAUTION: Use care when separating the cushion trim cover from the hook and loop strip, or the hook and loop strip can be torn from the cushion foam pad. Remove the cushion trim cover from the cushion foam pad. 7. To assemble, reverse the disassembly procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D Technical Service Bulletin # 06-13-6 Date: 060710 A/C - Climate Controlled Seats DTC B272C or B272D TSB 06-13-6 07/10/06 DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-14-10 to update the Service Procedure. ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs) B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various sources, making them difficult to diagnose. ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT061306 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14C724 42 Disclaimer Section 1 SECTION 1 1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General Procedures; Supplemental Restraint System Depowering and Repowering. 2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a, C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10554 3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS fails when activated in the heat mode. a. If the time to failure is 5 seconds or less then, proceed to Section 2. b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section 3. c. If the time to failure is 40 seconds or greater, then, proceed to Section 4. NOTE THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4 THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED. THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK. Section 2 SECTION 2 (Seat Shuts Off In Less Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system. a. If there is an over-temp DTC present then go to Step 3. b. If no over-temp DTC is present then go to Step 6. 3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go to Step 4. b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11. c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair as needed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10555 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger cushion) Figure 1.) a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM. b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms? (1) If no, then replace TED. (2) If yes, go to Step 5. 5. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then go to Step 6. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to Step 12. b. If not then proceed to Step 7. 7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then proceed to Step 8. b. If no, then go to Step 9 in Section 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10556 8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) a. If plugged in, then proceed to Step 9. b. If not plugged in, then correct and proceed to Step 12. 9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM). (Figure 2) a. If it is open, then proceed to Step 10. b. If it is not open, then proceed to Step 11. 10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the harnesses). a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step 12. b. If the wire harnesses are good, then proceed to Step 11. 11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms (proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room temperature)? a. No, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. Yes, then replace the DCCSM and proceed to Step 12. 12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to customer. Section 3 SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B). a. If there is an over-temp DTC present, then continue to Step 3. b. If there is no over-temp DTC present, then continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10557 c. If CCS is now operable, then repower the SRS and return vehicle to customer. 3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If readings are hotter than room temperature, go to Step 4. b. If TED temperatures between Back and Cushion are 100 different, go to Step 12. c. If reading correctly then, proceed to Step 5. 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion). (Figure 1) a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on. (1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground. (2) If yes, fix the wiring, if no replace the DCCSM. b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms? (1) If yes, go to Step 5. (2) If no, then replace TED. (Figure 2) 5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, go to Step 6. b. If no, go to Step 7. 6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to Pin 2. a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM, otherwise replace the harness. Verify system now functions and return vehicle to customer. b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system now functions and return vehicle to customer. 7. Cycle ignition and enter into high cool mode. Does failure still occur? a. If no, proceed to Step 8. b. If yes, proceed to Step 13. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10558 8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED connector. NOTE DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE a. If voltage is not getting to the suspect TED, proceed to Step 9. b. If voltage is getting to the suspect TED, replace TED. 9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the module. (Figure 3) ^ Driver Cushion - Pin 9 ^ Driver Backrest - Pin 8 ^ Passenger Cushion - Pin 11 ^ Passenger Backrest - Pin 22 a. If no voltage is coming out of the module, then replace the module and continue to Step 13. b. If the correct voltage is coming out of the module, then continue to Step 10. 10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found, then continue to Step 11. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10559 11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2 volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5) 12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms (proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room temperature)? a. If no, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. If yes, then proceed to Step 13. 13. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1. b. Time to failure is not different than before, then continue to Step 14. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10560 14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7) a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10561 b. If there are no kinks or obstructions of the ducting then, continue to Step 16. 15. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 16. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10562 16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been obstructed or damaged or bunched in the cushion blocking air flow from the TED. a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 17. b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then replace the TED and continue to Step 17. 17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer. Section 4 SECTION 4 (Seat Shuts Off After More Than 40 Seconds) 1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected seat when a heating cycle is initiated. a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2. b. If the TEDs both increase temperature, then proceed to Step 3. 2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED that does not increase temperature from Step 1. a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed to Step 3. b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED, verify the fix and proceed to Step 6. 3. Check for any kinks or obstructions of the ducting from the fan to the TED. a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible otherwise replace the ducting and continue to Step 4. b. If there are no kinks or obstructions of the ducting, then continue to Step 5. 4. If CCS continues to be inoperable with DTC B272C/D code and Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10563 a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 5. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion alignment is incorrect. a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6. b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6. c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 6. d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a climate control seat, then replace the TED and continue to Step 6. 6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer. Section 5 SECTION 5 (Spread Terminal Fix Procedure) 1. Position the front passenger seat fully rearward and up. 2. Pull out and remove the seat track front cover. 3. Disconnect Connector C3265B 24-pin gray. (Figure 3). 4. Remove the red secondary wedge inside the connector. 5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3). NOTE DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG CAVITY. 6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the terminal) and bend the spring into the proper position (Figure 10). 7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the connector. 8. Reconnect C3265B to the dual climate control seat module. 9. Reinstall the seat track front cover. 10. Repower the SRS. Refer to WSM, Section 501-20B. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10564 11. Verify the climate control seat function, and recheck DTCs. 12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D Technical Service Bulletin # 06-13-6 Date: 060710 A/C - Climate Controlled Seats DTC B272C or B272D TSB 06-13-6 07/10/06 DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-14-10 to update the Service Procedure. ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs) B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various sources, making them difficult to diagnose. ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT061306 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14C724 42 Disclaimer Section 1 SECTION 1 1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General Procedures; Supplemental Restraint System Depowering and Repowering. 2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a, C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10570 3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS fails when activated in the heat mode. a. If the time to failure is 5 seconds or less then, proceed to Section 2. b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section 3. c. If the time to failure is 40 seconds or greater, then, proceed to Section 4. NOTE THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4 THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED. THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK. Section 2 SECTION 2 (Seat Shuts Off In Less Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system. a. If there is an over-temp DTC present then go to Step 3. b. If no over-temp DTC is present then go to Step 6. 3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go to Step 4. b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11. c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair as needed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10571 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger cushion) Figure 1.) a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM. b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms? (1) If no, then replace TED. (2) If yes, go to Step 5. 5. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then go to Step 6. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to Step 12. b. If not then proceed to Step 7. 7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then proceed to Step 8. b. If no, then go to Step 9 in Section 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10572 8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) a. If plugged in, then proceed to Step 9. b. If not plugged in, then correct and proceed to Step 12. 9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM). (Figure 2) a. If it is open, then proceed to Step 10. b. If it is not open, then proceed to Step 11. 10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the harnesses). a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step 12. b. If the wire harnesses are good, then proceed to Step 11. 11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms (proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room temperature)? a. No, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. Yes, then replace the DCCSM and proceed to Step 12. 12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to customer. Section 3 SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B). a. If there is an over-temp DTC present, then continue to Step 3. b. If there is no over-temp DTC present, then continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10573 c. If CCS is now operable, then repower the SRS and return vehicle to customer. 3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If readings are hotter than room temperature, go to Step 4. b. If TED temperatures between Back and Cushion are 100 different, go to Step 12. c. If reading correctly then, proceed to Step 5. 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion). (Figure 1) a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on. (1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground. (2) If yes, fix the wiring, if no replace the DCCSM. b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms? (1) If yes, go to Step 5. (2) If no, then replace TED. (Figure 2) 5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, go to Step 6. b. If no, go to Step 7. 6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to Pin 2. a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM, otherwise replace the harness. Verify system now functions and return vehicle to customer. b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system now functions and return vehicle to customer. 7. Cycle ignition and enter into high cool mode. Does failure still occur? a. If no, proceed to Step 8. b. If yes, proceed to Step 13. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10574 8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED connector. NOTE DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE a. If voltage is not getting to the suspect TED, proceed to Step 9. b. If voltage is getting to the suspect TED, replace TED. 9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the module. (Figure 3) ^ Driver Cushion - Pin 9 ^ Driver Backrest - Pin 8 ^ Passenger Cushion - Pin 11 ^ Passenger Backrest - Pin 22 a. If no voltage is coming out of the module, then replace the module and continue to Step 13. b. If the correct voltage is coming out of the module, then continue to Step 10. 10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found, then continue to Step 11. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10575 11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2 volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5) 12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms (proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room temperature)? a. If no, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. If yes, then proceed to Step 13. 13. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1. b. Time to failure is not different than before, then continue to Step 14. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10576 14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7) a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10577 b. If there are no kinks or obstructions of the ducting then, continue to Step 16. 15. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 16. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10578 16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been obstructed or damaged or bunched in the cushion blocking air flow from the TED. a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 17. b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then replace the TED and continue to Step 17. 17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer. Section 4 SECTION 4 (Seat Shuts Off After More Than 40 Seconds) 1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected seat when a heating cycle is initiated. a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2. b. If the TEDs both increase temperature, then proceed to Step 3. 2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED that does not increase temperature from Step 1. a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed to Step 3. b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED, verify the fix and proceed to Step 6. 3. Check for any kinks or obstructions of the ducting from the fan to the TED. a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible otherwise replace the ducting and continue to Step 4. b. If there are no kinks or obstructions of the ducting, then continue to Step 5. 4. If CCS continues to be inoperable with DTC B272C/D code and Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10579 a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 5. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion alignment is incorrect. a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6. b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6. c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 6. d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a climate control seat, then replace the TED and continue to Step 6. 6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer. Section 5 SECTION 5 (Spread Terminal Fix Procedure) 1. Position the front passenger seat fully rearward and up. 2. Pull out and remove the seat track front cover. 3. Disconnect Connector C3265B 24-pin gray. (Figure 3). 4. Remove the red secondary wedge inside the connector. 5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3). NOTE DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG CAVITY. 6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the terminal) and bend the spring into the proper position (Figure 10). 7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the connector. 8. Reconnect C3265B to the dual climate control seat module. 9. Reinstall the seat track front cover. 10. Repower the SRS. Refer to WSM, Section 501-20B. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10580 11. Verify the climate control seat function, and recheck DTCs. 12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions Seat Heater: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10583 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10584 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10585 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10586 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10587 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10588 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10589 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10590 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10591 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10592 Seat Heater: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10593 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10594 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10595 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10596 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10597 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10598 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10599 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10600 Seat Heater: Connector Views C3034 C3039 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10601 C3035 C3040 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10602 C3033 C3038 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10603 Seat Heater: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 119-1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 10604 119-2 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. See: Diagrams/Components/Component Location Views Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat Backrest Thermo-Electric Device Seat Heater: Service and Repair Seat Backrest Thermo-Electric Device SEAT BACKREST THERMO-ELECTRIC DEVICE Removal and Installation WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Position the seat to gain access to all seat track-to-floor fasteners. 2. Depower the SRS. 3. Remove the 40 percent seat. 4. From under the seat, disconnect the seat backrest thermo-electric device (TED) electrical connector at the seat cushion frame. 5. Remove lower backrest cover. 6. Remove the 2 screws and the securing strap. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat Backrest Thermo-Electric Device > Page 10607 7. Release the backrest trim cover hook-and-loop strip and J-clip. 8. Depress the head restraint guide tab and remove the head restraint. 9. NOTE: The head restraint guides are not interchangeable. Note location for installation. Reach up into backrest and squeeze the head restraint guide ends together to release and pull the 2 head restraint guides out. 10. CAUTION: Use care when separating the seat backrest trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat backrest foam. Invert the backrest trim cover and remove. 11. CAUTION: Use care when removing the backrest foam pad from the frame. The foam pad has hook and loop fasteners holding the thermo-electric device to the backrest foam pad. Separate the backrest foam pad from the backrest thermo-electric device and remove the backrest foam pad. 12. Route the backrest TED wire harness back through the seat cushion and trim cover. 13. Remove the backrest TED. - Remove the backrest TED wire harness pin-type retainers. - Cut the zip-ties and separate the ducts from the backrest TED. - Remove the backrest TED. 14. To install, reverse the removal procedure. 15. Install the 40 percent seat. 16. Repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat Backrest Thermo-Electric Device > Page 10608 Seat Heater: Service and Repair Seat Cushion Thermo-Electric Device SEAT CUSHION THERMO-ELECTRIC DEVICE Removal and Installation WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Position the seat to gain access to all seat track-to-floor fasteners. 2. Depower the SRS. 3. Remove the 40 percent seat. 4. Remove the seat side shield. 5. Remove the seat fan motor. 6. Remove the front height power seat motor. 7. Release the cushion trim cover J-clips (6 shown). 8. CAUTION: Use care when separating the seat cushion trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat cushion. Remove the seat cushion trim cover. 9. Remove the seat cushion foam pad. 10. Remove the screw and separate the seat cushion thermo-electric device (TED) from the mounting bezel. 11. Remove the cushion TED. - Cut the zip-tie, separate and remove the supply duct. - Disconnect the seat cushion TED electrical connector. - Remove the seat cushion TED. 12. To install, reverse the removal procedure. 13. Install the front height power seat motor. 14. Install the seat fan motor. 15. Install the seat side shield. 16. Install the 40 percent seat. 17. Repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Seat Backrest Thermo-Electric Device > Page 10609 Seat Heater: Service and Repair Seat Fan Motor SEAT FAN MOTOR Removal and Installation WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Position the seat to gain access to all seat track-to-floor fasteners. 2. Depower the SRS. 3. Remove the 40 percent seat. 4. Remove the seat fan motor. - Cut the zip-tie and separate the duct from the seat fan motor. - Cut the zip-tie and separate the duct from the seat fan motor. - Disconnect the seat fan motor wire harness electrical connector. - Remove the 4 screws. - Remove the fan motor. 5. To install, reverse the removal procedure. 6. Install the 40 percent seat. 7. Repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D Technical Service Bulletin # 06-13-6 Date: 060710 A/C - Climate Controlled Seats DTC B272C or B272D TSB 06-13-6 07/10/06 DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-14-10 to update the Service Procedure. ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs) B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various sources, making them difficult to diagnose. ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT061306 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14C724 42 Disclaimer Section 1 SECTION 1 1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General Procedures; Supplemental Restraint System Depowering and Repowering. 2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a, C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10618 3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS fails when activated in the heat mode. a. If the time to failure is 5 seconds or less then, proceed to Section 2. b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section 3. c. If the time to failure is 40 seconds or greater, then, proceed to Section 4. NOTE THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4 THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED. THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK. Section 2 SECTION 2 (Seat Shuts Off In Less Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system. a. If there is an over-temp DTC present then go to Step 3. b. If no over-temp DTC is present then go to Step 6. 3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go to Step 4. b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11. c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair as needed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10619 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger cushion) Figure 1.) a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM. b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms? (1) If no, then replace TED. (2) If yes, go to Step 5. 5. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then go to Step 6. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to Step 12. b. If not then proceed to Step 7. 7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then proceed to Step 8. b. If no, then go to Step 9 in Section 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10620 8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) a. If plugged in, then proceed to Step 9. b. If not plugged in, then correct and proceed to Step 12. 9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM). (Figure 2) a. If it is open, then proceed to Step 10. b. If it is not open, then proceed to Step 11. 10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the harnesses). a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step 12. b. If the wire harnesses are good, then proceed to Step 11. 11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms (proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room temperature)? a. No, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. Yes, then replace the DCCSM and proceed to Step 12. 12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to customer. Section 3 SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B). a. If there is an over-temp DTC present, then continue to Step 3. b. If there is no over-temp DTC present, then continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10621 c. If CCS is now operable, then repower the SRS and return vehicle to customer. 3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If readings are hotter than room temperature, go to Step 4. b. If TED temperatures between Back and Cushion are 100 different, go to Step 12. c. If reading correctly then, proceed to Step 5. 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion). (Figure 1) a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on. (1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground. (2) If yes, fix the wiring, if no replace the DCCSM. b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms? (1) If yes, go to Step 5. (2) If no, then replace TED. (Figure 2) 5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, go to Step 6. b. If no, go to Step 7. 6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to Pin 2. a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM, otherwise replace the harness. Verify system now functions and return vehicle to customer. b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system now functions and return vehicle to customer. 7. Cycle ignition and enter into high cool mode. Does failure still occur? a. If no, proceed to Step 8. b. If yes, proceed to Step 13. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10622 8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED connector. NOTE DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE a. If voltage is not getting to the suspect TED, proceed to Step 9. b. If voltage is getting to the suspect TED, replace TED. 9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the module. (Figure 3) ^ Driver Cushion - Pin 9 ^ Driver Backrest - Pin 8 ^ Passenger Cushion - Pin 11 ^ Passenger Backrest - Pin 22 a. If no voltage is coming out of the module, then replace the module and continue to Step 13. b. If the correct voltage is coming out of the module, then continue to Step 10. 10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found, then continue to Step 11. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10623 11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2 volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5) 12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms (proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room temperature)? a. If no, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. If yes, then proceed to Step 13. 13. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1. b. Time to failure is not different than before, then continue to Step 14. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10624 14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7) a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10625 b. If there are no kinks or obstructions of the ducting then, continue to Step 16. 15. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 16. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10626 16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been obstructed or damaged or bunched in the cushion blocking air flow from the TED. a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 17. b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then replace the TED and continue to Step 17. 17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer. Section 4 SECTION 4 (Seat Shuts Off After More Than 40 Seconds) 1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected seat when a heating cycle is initiated. a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2. b. If the TEDs both increase temperature, then proceed to Step 3. 2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED that does not increase temperature from Step 1. a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed to Step 3. b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED, verify the fix and proceed to Step 6. 3. Check for any kinks or obstructions of the ducting from the fan to the TED. a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible otherwise replace the ducting and continue to Step 4. b. If there are no kinks or obstructions of the ducting, then continue to Step 5. 4. If CCS continues to be inoperable with DTC B272C/D code and Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10627 a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 5. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion alignment is incorrect. a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6. b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6. c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 6. d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a climate control seat, then replace the TED and continue to Step 6. 6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer. Section 5 SECTION 5 (Spread Terminal Fix Procedure) 1. Position the front passenger seat fully rearward and up. 2. Pull out and remove the seat track front cover. 3. Disconnect Connector C3265B 24-pin gray. (Figure 3). 4. Remove the red secondary wedge inside the connector. 5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3). NOTE DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG CAVITY. 6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the terminal) and bend the spring into the proper position (Figure 10). 7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the connector. 8. Reconnect C3265B to the dual climate control seat module. 9. Reinstall the seat track front cover. 10. Repower the SRS. Refer to WSM, Section 501-20B. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10628 11. Verify the climate control seat function, and recheck DTCs. 12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D Technical Service Bulletin # 06-13-6 Date: 060710 A/C - Climate Controlled Seats DTC B272C or B272D TSB 06-13-6 07/10/06 DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-14-10 to update the Service Procedure. ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs) B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various sources, making them difficult to diagnose. ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT061306 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14C724 42 Disclaimer Section 1 SECTION 1 1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General Procedures; Supplemental Restraint System Depowering and Repowering. 2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a, C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10634 3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS fails when activated in the heat mode. a. If the time to failure is 5 seconds or less then, proceed to Section 2. b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section 3. c. If the time to failure is 40 seconds or greater, then, proceed to Section 4. NOTE THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4 THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED. THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK. Section 2 SECTION 2 (Seat Shuts Off In Less Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system. a. If there is an over-temp DTC present then go to Step 3. b. If no over-temp DTC is present then go to Step 6. 3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go to Step 4. b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11. c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair as needed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10635 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger cushion) Figure 1.) a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM. b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms? (1) If no, then replace TED. (2) If yes, go to Step 5. 5. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then go to Step 6. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to Step 12. b. If not then proceed to Step 7. 7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then proceed to Step 8. b. If no, then go to Step 9 in Section 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10636 8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) a. If plugged in, then proceed to Step 9. b. If not plugged in, then correct and proceed to Step 12. 9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM). (Figure 2) a. If it is open, then proceed to Step 10. b. If it is not open, then proceed to Step 11. 10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the harnesses). a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step 12. b. If the wire harnesses are good, then proceed to Step 11. 11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms (proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room temperature)? a. No, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. Yes, then replace the DCCSM and proceed to Step 12. 12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to customer. Section 3 SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B). a. If there is an over-temp DTC present, then continue to Step 3. b. If there is no over-temp DTC present, then continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10637 c. If CCS is now operable, then repower the SRS and return vehicle to customer. 3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If readings are hotter than room temperature, go to Step 4. b. If TED temperatures between Back and Cushion are 100 different, go to Step 12. c. If reading correctly then, proceed to Step 5. 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion). (Figure 1) a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on. (1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground. (2) If yes, fix the wiring, if no replace the DCCSM. b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms? (1) If yes, go to Step 5. (2) If no, then replace TED. (Figure 2) 5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, go to Step 6. b. If no, go to Step 7. 6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to Pin 2. a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM, otherwise replace the harness. Verify system now functions and return vehicle to customer. b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system now functions and return vehicle to customer. 7. Cycle ignition and enter into high cool mode. Does failure still occur? a. If no, proceed to Step 8. b. If yes, proceed to Step 13. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10638 8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED connector. NOTE DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE a. If voltage is not getting to the suspect TED, proceed to Step 9. b. If voltage is getting to the suspect TED, replace TED. 9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the module. (Figure 3) ^ Driver Cushion - Pin 9 ^ Driver Backrest - Pin 8 ^ Passenger Cushion - Pin 11 ^ Passenger Backrest - Pin 22 a. If no voltage is coming out of the module, then replace the module and continue to Step 13. b. If the correct voltage is coming out of the module, then continue to Step 10. 10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found, then continue to Step 11. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10639 11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2 volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5) 12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms (proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room temperature)? a. If no, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. If yes, then proceed to Step 13. 13. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1. b. Time to failure is not different than before, then continue to Step 14. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10640 14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7) a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10641 b. If there are no kinks or obstructions of the ducting then, continue to Step 16. 15. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 16. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10642 16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been obstructed or damaged or bunched in the cushion blocking air flow from the TED. a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 17. b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then replace the TED and continue to Step 17. 17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer. Section 4 SECTION 4 (Seat Shuts Off After More Than 40 Seconds) 1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected seat when a heating cycle is initiated. a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2. b. If the TEDs both increase temperature, then proceed to Step 3. 2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED that does not increase temperature from Step 1. a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed to Step 3. b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED, verify the fix and proceed to Step 6. 3. Check for any kinks or obstructions of the ducting from the fan to the TED. a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible otherwise replace the ducting and continue to Step 4. b. If there are no kinks or obstructions of the ducting, then continue to Step 5. 4. If CCS continues to be inoperable with DTC B272C/D code and Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10643 a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 5. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion alignment is incorrect. a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6. b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6. c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 6. d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a climate control seat, then replace the TED and continue to Step 6. 6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer. Section 5 SECTION 5 (Spread Terminal Fix Procedure) 1. Position the front passenger seat fully rearward and up. 2. Pull out and remove the seat track front cover. 3. Disconnect Connector C3265B 24-pin gray. (Figure 3). 4. Remove the red secondary wedge inside the connector. 5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3). NOTE DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG CAVITY. 6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the terminal) and bend the spring into the proper position (Figure 10). 7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the connector. 8. Reconnect C3265B to the dual climate control seat module. 9. Reinstall the seat track front cover. 10. Repower the SRS. Refer to WSM, Section 501-20B. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10644 11. Verify the climate control seat function, and recheck DTCs. 12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 10645 View 151-27 (Passenger Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 10646 Seat Heater Control Module: Diagrams C3265a Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 10647 C3265b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 10648 Seat Heater Control Module: Service and Repair CLIMATE CONTROLLED SEAT MODULE Removal and Installation WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - When installing a new climate control seat module (CCSM), it is necessary to carry out programmable module installation (PMI). 1. Before removing the dual CCSM, carry out the appropriate steps in the PMI procedure. 2. Position the front passenger seat all the way back and up. 3. Depower the SRS. 4. Pull out and remove the seat track front cover. 5. NOTE: The inset shows the dual climate control seat module (CCSM) retaining bracket. Remove the dual CCSM. 1 Pull the back of the dual CCSM away from the seat and slide it off the mounting bracket. 2 Disconnect the electrical connectors. 3 Remove the dual CCSM. 6. To install, reverse the removal procedure. 7. Repower the SRS. 8. Install the CCSM software data. Carry out the appropriate steps in the PMI procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D Technical Service Bulletin # 06-13-6 Date: 060710 A/C - Climate Controlled Seats DTC B272C or B272D TSB 06-13-6 07/10/06 DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-14-10 to update the Service Procedure. ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs) B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various sources, making them difficult to diagnose. ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT061306 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14C724 42 Disclaimer Section 1 SECTION 1 1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General Procedures; Supplemental Restraint System Depowering and Repowering. 2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a, C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10657 3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS fails when activated in the heat mode. a. If the time to failure is 5 seconds or less then, proceed to Section 2. b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section 3. c. If the time to failure is 40 seconds or greater, then, proceed to Section 4. NOTE THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4 THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED. THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK. Section 2 SECTION 2 (Seat Shuts Off In Less Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system. a. If there is an over-temp DTC present then go to Step 3. b. If no over-temp DTC is present then go to Step 6. 3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go to Step 4. b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11. c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair as needed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10658 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger cushion) Figure 1.) a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM. b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms? (1) If no, then replace TED. (2) If yes, go to Step 5. 5. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then go to Step 6. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to Step 12. b. If not then proceed to Step 7. 7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then proceed to Step 8. b. If no, then go to Step 9 in Section 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10659 8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) a. If plugged in, then proceed to Step 9. b. If not plugged in, then correct and proceed to Step 12. 9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM). (Figure 2) a. If it is open, then proceed to Step 10. b. If it is not open, then proceed to Step 11. 10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the harnesses). a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step 12. b. If the wire harnesses are good, then proceed to Step 11. 11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms (proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room temperature)? a. No, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. Yes, then replace the DCCSM and proceed to Step 12. 12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to customer. Section 3 SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B). a. If there is an over-temp DTC present, then continue to Step 3. b. If there is no over-temp DTC present, then continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10660 c. If CCS is now operable, then repower the SRS and return vehicle to customer. 3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If readings are hotter than room temperature, go to Step 4. b. If TED temperatures between Back and Cushion are 100 different, go to Step 12. c. If reading correctly then, proceed to Step 5. 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion). (Figure 1) a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on. (1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground. (2) If yes, fix the wiring, if no replace the DCCSM. b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms? (1) If yes, go to Step 5. (2) If no, then replace TED. (Figure 2) 5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, go to Step 6. b. If no, go to Step 7. 6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to Pin 2. a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM, otherwise replace the harness. Verify system now functions and return vehicle to customer. b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system now functions and return vehicle to customer. 7. Cycle ignition and enter into high cool mode. Does failure still occur? a. If no, proceed to Step 8. b. If yes, proceed to Step 13. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10661 8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED connector. NOTE DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE a. If voltage is not getting to the suspect TED, proceed to Step 9. b. If voltage is getting to the suspect TED, replace TED. 9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the module. (Figure 3) ^ Driver Cushion - Pin 9 ^ Driver Backrest - Pin 8 ^ Passenger Cushion - Pin 11 ^ Passenger Backrest - Pin 22 a. If no voltage is coming out of the module, then replace the module and continue to Step 13. b. If the correct voltage is coming out of the module, then continue to Step 10. 10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found, then continue to Step 11. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10662 11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2 volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5) 12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms (proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room temperature)? a. If no, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. If yes, then proceed to Step 13. 13. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1. b. Time to failure is not different than before, then continue to Step 14. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10663 14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7) a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10664 b. If there are no kinks or obstructions of the ducting then, continue to Step 16. 15. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 16. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10665 16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been obstructed or damaged or bunched in the cushion blocking air flow from the TED. a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 17. b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then replace the TED and continue to Step 17. 17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer. Section 4 SECTION 4 (Seat Shuts Off After More Than 40 Seconds) 1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected seat when a heating cycle is initiated. a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2. b. If the TEDs both increase temperature, then proceed to Step 3. 2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED that does not increase temperature from Step 1. a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed to Step 3. b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED, verify the fix and proceed to Step 6. 3. Check for any kinks or obstructions of the ducting from the fan to the TED. a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible otherwise replace the ducting and continue to Step 4. b. If there are no kinks or obstructions of the ducting, then continue to Step 5. 4. If CCS continues to be inoperable with DTC B272C/D code and Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10666 a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 5. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion alignment is incorrect. a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6. b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6. c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 6. d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a climate control seat, then replace the TED and continue to Step 6. 6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer. Section 5 SECTION 5 (Spread Terminal Fix Procedure) 1. Position the front passenger seat fully rearward and up. 2. Pull out and remove the seat track front cover. 3. Disconnect Connector C3265B 24-pin gray. (Figure 3). 4. Remove the red secondary wedge inside the connector. 5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3). NOTE DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG CAVITY. 6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the terminal) and bend the spring into the proper position (Figure 10). 7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the connector. 8. Reconnect C3265B to the dual climate control seat module. 9. Reinstall the seat track front cover. 10. Repower the SRS. Refer to WSM, Section 501-20B. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10667 11. Verify the climate control seat function, and recheck DTCs. 12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-21-3 > Oct > 08 > A/C - Inoperative/Blows Warm Air Compressor Clutch Hub: All Technical Service Bulletins A/C - Inoperative/Blows Warm Air TSB 08-21-3 10/27/08 A/C SYSTEM BLOWS WARM/INOPERATIVE - HIGH AMBIENT TEMPERATURES, EXTENDED IDLE TIMES, TRAILER TOW, DUSTY CLIMATES OR OFF ROAD USE FORD: 2006 Expedition LINCOLN: 2006 Navigator ISSUE Some 2006 Expedition and Navigator vehicles equipped with A/C may become inoperative or blow warm air due to an open electrical circuit of the A/C compressor field coil in high ambient temperatures, extended idle times, trailer tow, dusty climates or off road use. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Replace the A/C clutch disc, field coil and compressor pulley, using the part numbers below. The replacing parts are larger in diameter. Failure to use the part numbers listed below together may cause repeat failure. 1. Recover A/C refrigerant per Workshop Manual (WSM), Section 412-00. 2. Replace the A/C compressor clutch, field coil and pulley per WSM, Section 412-01. 3. Recharge A/C system per WSM, Section 412-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082103A 2006 Expedition 4X2, 1.4 Hrs. Navigator 4X2/4X4: Replace the A/C compressor clutch, field coil and pulley, Includes Time To Remove and Install Compressor (Do Not Use With 19700A, 19700A4) 082103A 2006 Expedition 4X4: 1.6 Hrs. Replace the A/C compressor clutch, field coil and pulley, Includes Time To Remove and Install Compressor (Do Not Use With 19700A, 19700A4) DEALER CODING CONDITION BASIC PART NO. CODE 19D798 28 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-21-3 > Oct > 08 > A/C - Inoperative/Blows Warm Air > Page 10673 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 08-21-3 > Oct > 08 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D Technical Service Bulletin # 06-13-6 Date: 060710 A/C - Climate Controlled Seats DTC B272C or B272D TSB 06-13-6 07/10/06 DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-14-10 to update the Service Procedure. ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs) B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various sources, making them difficult to diagnose. ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT061306 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14C724 42 Disclaimer Section 1 SECTION 1 1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General Procedures; Supplemental Restraint System Depowering and Repowering. 2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a, C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 08-21-3 > Oct > 08 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10683 3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS fails when activated in the heat mode. a. If the time to failure is 5 seconds or less then, proceed to Section 2. b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section 3. c. If the time to failure is 40 seconds or greater, then, proceed to Section 4. NOTE THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4 THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED. THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK. Section 2 SECTION 2 (Seat Shuts Off In Less Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system. a. If there is an over-temp DTC present then go to Step 3. b. If no over-temp DTC is present then go to Step 6. 3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go to Step 4. b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11. c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair as needed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 08-21-3 > Oct > 08 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10684 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger cushion) Figure 1.) a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM. b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms? (1) If no, then replace TED. (2) If yes, go to Step 5. 5. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then go to Step 6. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to Step 12. b. If not then proceed to Step 7. 7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then proceed to Step 8. b. If no, then go to Step 9 in Section 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 08-21-3 > Oct > 08 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10685 8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) a. If plugged in, then proceed to Step 9. b. If not plugged in, then correct and proceed to Step 12. 9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM). (Figure 2) a. If it is open, then proceed to Step 10. b. If it is not open, then proceed to Step 11. 10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the harnesses). a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step 12. b. If the wire harnesses are good, then proceed to Step 11. 11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms (proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room temperature)? a. No, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. Yes, then replace the DCCSM and proceed to Step 12. 12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to customer. Section 3 SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B). a. If there is an over-temp DTC present, then continue to Step 3. b. If there is no over-temp DTC present, then continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 08-21-3 > Oct > 08 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10686 c. If CCS is now operable, then repower the SRS and return vehicle to customer. 3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If readings are hotter than room temperature, go to Step 4. b. If TED temperatures between Back and Cushion are 100 different, go to Step 12. c. If reading correctly then, proceed to Step 5. 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion). (Figure 1) a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on. (1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground. (2) If yes, fix the wiring, if no replace the DCCSM. b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms? (1) If yes, go to Step 5. (2) If no, then replace TED. (Figure 2) 5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, go to Step 6. b. If no, go to Step 7. 6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to Pin 2. a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM, otherwise replace the harness. Verify system now functions and return vehicle to customer. b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system now functions and return vehicle to customer. 7. Cycle ignition and enter into high cool mode. Does failure still occur? a. If no, proceed to Step 8. b. If yes, proceed to Step 13. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 08-21-3 > Oct > 08 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10687 8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED connector. NOTE DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE a. If voltage is not getting to the suspect TED, proceed to Step 9. b. If voltage is getting to the suspect TED, replace TED. 9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the module. (Figure 3) ^ Driver Cushion - Pin 9 ^ Driver Backrest - Pin 8 ^ Passenger Cushion - Pin 11 ^ Passenger Backrest - Pin 22 a. If no voltage is coming out of the module, then replace the module and continue to Step 13. b. If the correct voltage is coming out of the module, then continue to Step 10. 10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found, then continue to Step 11. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 08-21-3 > Oct > 08 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10688 11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2 volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5) 12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms (proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room temperature)? a. If no, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. If yes, then proceed to Step 13. 13. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1. b. Time to failure is not different than before, then continue to Step 14. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 08-21-3 > Oct > 08 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10689 14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7) a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 08-21-3 > Oct > 08 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10690 b. If there are no kinks or obstructions of the ducting then, continue to Step 16. 15. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 16. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 08-21-3 > Oct > 08 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10691 16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been obstructed or damaged or bunched in the cushion blocking air flow from the TED. a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 17. b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then replace the TED and continue to Step 17. 17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer. Section 4 SECTION 4 (Seat Shuts Off After More Than 40 Seconds) 1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected seat when a heating cycle is initiated. a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2. b. If the TEDs both increase temperature, then proceed to Step 3. 2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED that does not increase temperature from Step 1. a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed to Step 3. b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED, verify the fix and proceed to Step 6. 3. Check for any kinks or obstructions of the ducting from the fan to the TED. a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible otherwise replace the ducting and continue to Step 4. b. If there are no kinks or obstructions of the ducting, then continue to Step 5. 4. If CCS continues to be inoperable with DTC B272C/D code and Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 08-21-3 > Oct > 08 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10692 a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 5. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion alignment is incorrect. a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6. b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6. c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 6. d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a climate control seat, then replace the TED and continue to Step 6. 6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer. Section 5 SECTION 5 (Spread Terminal Fix Procedure) 1. Position the front passenger seat fully rearward and up. 2. Pull out and remove the seat track front cover. 3. Disconnect Connector C3265B 24-pin gray. (Figure 3). 4. Remove the red secondary wedge inside the connector. 5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3). NOTE DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG CAVITY. 6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the terminal) and bend the spring into the proper position (Figure 10). 7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the connector. 8. Reconnect C3265B to the dual climate control seat module. 9. Reinstall the seat track front cover. 10. Repower the SRS. Refer to WSM, Section 501-20B. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Relay: > 08-21-3 > Oct > 08 > Customer Interest for Seat Heater Relay: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10693 11. Verify the climate control seat function, and recheck DTCs. 12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor Clutch Hub: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D Technical Service Bulletin # 06-13-6 Date: 060710 A/C - Climate Controlled Seats DTC B272C or B272D TSB 06-13-6 07/10/06 DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-14-10 to update the Service Procedure. ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs) B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various sources, making them difficult to diagnose. ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT061306 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14C724 42 Disclaimer Section 1 SECTION 1 1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General Procedures; Supplemental Restraint System Depowering and Repowering. 2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a, C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor Clutch Hub: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10699 3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS fails when activated in the heat mode. a. If the time to failure is 5 seconds or less then, proceed to Section 2. b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section 3. c. If the time to failure is 40 seconds or greater, then, proceed to Section 4. NOTE THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4 THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED. THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK. Section 2 SECTION 2 (Seat Shuts Off In Less Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system. a. If there is an over-temp DTC present then go to Step 3. b. If no over-temp DTC is present then go to Step 6. 3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go to Step 4. b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11. c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair as needed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor Clutch Hub: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10700 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger cushion) Figure 1.) a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM. b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms? (1) If no, then replace TED. (2) If yes, go to Step 5. 5. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then go to Step 6. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to Step 12. b. If not then proceed to Step 7. 7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then proceed to Step 8. b. If no, then go to Step 9 in Section 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor Clutch Hub: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10701 8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) a. If plugged in, then proceed to Step 9. b. If not plugged in, then correct and proceed to Step 12. 9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM). (Figure 2) a. If it is open, then proceed to Step 10. b. If it is not open, then proceed to Step 11. 10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the harnesses). a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step 12. b. If the wire harnesses are good, then proceed to Step 11. 11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms (proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room temperature)? a. No, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. Yes, then replace the DCCSM and proceed to Step 12. 12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to customer. Section 3 SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B). a. If there is an over-temp DTC present, then continue to Step 3. b. If there is no over-temp DTC present, then continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor Clutch Hub: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10702 c. If CCS is now operable, then repower the SRS and return vehicle to customer. 3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If readings are hotter than room temperature, go to Step 4. b. If TED temperatures between Back and Cushion are 100 different, go to Step 12. c. If reading correctly then, proceed to Step 5. 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion). (Figure 1) a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on. (1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground. (2) If yes, fix the wiring, if no replace the DCCSM. b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms? (1) If yes, go to Step 5. (2) If no, then replace TED. (Figure 2) 5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, go to Step 6. b. If no, go to Step 7. 6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to Pin 2. a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM, otherwise replace the harness. Verify system now functions and return vehicle to customer. b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system now functions and return vehicle to customer. 7. Cycle ignition and enter into high cool mode. Does failure still occur? a. If no, proceed to Step 8. b. If yes, proceed to Step 13. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor Clutch Hub: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10703 8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED connector. NOTE DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE a. If voltage is not getting to the suspect TED, proceed to Step 9. b. If voltage is getting to the suspect TED, replace TED. 9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the module. (Figure 3) ^ Driver Cushion - Pin 9 ^ Driver Backrest - Pin 8 ^ Passenger Cushion - Pin 11 ^ Passenger Backrest - Pin 22 a. If no voltage is coming out of the module, then replace the module and continue to Step 13. b. If the correct voltage is coming out of the module, then continue to Step 10. 10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found, then continue to Step 11. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor Clutch Hub: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10704 11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2 volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5) 12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms (proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room temperature)? a. If no, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. If yes, then proceed to Step 13. 13. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1. b. Time to failure is not different than before, then continue to Step 14. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor Clutch Hub: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10705 14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7) a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor Clutch Hub: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10706 b. If there are no kinks or obstructions of the ducting then, continue to Step 16. 15. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 16. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor Clutch Hub: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10707 16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been obstructed or damaged or bunched in the cushion blocking air flow from the TED. a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 17. b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then replace the TED and continue to Step 17. 17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer. Section 4 SECTION 4 (Seat Shuts Off After More Than 40 Seconds) 1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected seat when a heating cycle is initiated. a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2. b. If the TEDs both increase temperature, then proceed to Step 3. 2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED that does not increase temperature from Step 1. a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed to Step 3. b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED, verify the fix and proceed to Step 6. 3. Check for any kinks or obstructions of the ducting from the fan to the TED. a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible otherwise replace the ducting and continue to Step 4. b. If there are no kinks or obstructions of the ducting, then continue to Step 5. 4. If CCS continues to be inoperable with DTC B272C/D code and Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor Clutch Hub: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10708 a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 5. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion alignment is incorrect. a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6. b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6. c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 6. d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a climate control seat, then replace the TED and continue to Step 6. 6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer. Section 5 SECTION 5 (Spread Terminal Fix Procedure) 1. Position the front passenger seat fully rearward and up. 2. Pull out and remove the seat track front cover. 3. Disconnect Connector C3265B 24-pin gray. (Figure 3). 4. Remove the red secondary wedge inside the connector. 5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3). NOTE DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG CAVITY. 6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the terminal) and bend the spring into the proper position (Figure 10). 7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the connector. 8. Reconnect C3265B to the dual climate control seat module. 9. Reinstall the seat track front cover. 10. Repower the SRS. Refer to WSM, Section 501-20B. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor Clutch Hub: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10709 11. Verify the climate control seat function, and recheck DTCs. 12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D Technical Service Bulletin # 06-13-6 Date: 060710 A/C - Climate Controlled Seats DTC B272C or B272D TSB 06-13-6 07/10/06 DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-14-10 to update the Service Procedure. ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs) B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various sources, making them difficult to diagnose. ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT061306 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14C724 42 Disclaimer Section 1 SECTION 1 1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General Procedures; Supplemental Restraint System Depowering and Repowering. 2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a, C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10718 3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS fails when activated in the heat mode. a. If the time to failure is 5 seconds or less then, proceed to Section 2. b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section 3. c. If the time to failure is 40 seconds or greater, then, proceed to Section 4. NOTE THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4 THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED. THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK. Section 2 SECTION 2 (Seat Shuts Off In Less Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system. a. If there is an over-temp DTC present then go to Step 3. b. If no over-temp DTC is present then go to Step 6. 3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go to Step 4. b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11. c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair as needed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10719 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger cushion) Figure 1.) a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM. b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms? (1) If no, then replace TED. (2) If yes, go to Step 5. 5. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then go to Step 6. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to Step 12. b. If not then proceed to Step 7. 7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then proceed to Step 8. b. If no, then go to Step 9 in Section 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10720 8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) a. If plugged in, then proceed to Step 9. b. If not plugged in, then correct and proceed to Step 12. 9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM). (Figure 2) a. If it is open, then proceed to Step 10. b. If it is not open, then proceed to Step 11. 10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the harnesses). a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step 12. b. If the wire harnesses are good, then proceed to Step 11. 11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms (proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room temperature)? a. No, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. Yes, then replace the DCCSM and proceed to Step 12. 12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to customer. Section 3 SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B). a. If there is an over-temp DTC present, then continue to Step 3. b. If there is no over-temp DTC present, then continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10721 c. If CCS is now operable, then repower the SRS and return vehicle to customer. 3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If readings are hotter than room temperature, go to Step 4. b. If TED temperatures between Back and Cushion are 100 different, go to Step 12. c. If reading correctly then, proceed to Step 5. 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion). (Figure 1) a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on. (1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground. (2) If yes, fix the wiring, if no replace the DCCSM. b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms? (1) If yes, go to Step 5. (2) If no, then replace TED. (Figure 2) 5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, go to Step 6. b. If no, go to Step 7. 6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to Pin 2. a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM, otherwise replace the harness. Verify system now functions and return vehicle to customer. b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system now functions and return vehicle to customer. 7. Cycle ignition and enter into high cool mode. Does failure still occur? a. If no, proceed to Step 8. b. If yes, proceed to Step 13. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10722 8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED connector. NOTE DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE a. If voltage is not getting to the suspect TED, proceed to Step 9. b. If voltage is getting to the suspect TED, replace TED. 9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the module. (Figure 3) ^ Driver Cushion - Pin 9 ^ Driver Backrest - Pin 8 ^ Passenger Cushion - Pin 11 ^ Passenger Backrest - Pin 22 a. If no voltage is coming out of the module, then replace the module and continue to Step 13. b. If the correct voltage is coming out of the module, then continue to Step 10. 10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found, then continue to Step 11. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10723 11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2 volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5) 12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms (proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room temperature)? a. If no, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. If yes, then proceed to Step 13. 13. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1. b. Time to failure is not different than before, then continue to Step 14. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10724 14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7) a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10725 b. If there are no kinks or obstructions of the ducting then, continue to Step 16. 15. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 16. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10726 16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been obstructed or damaged or bunched in the cushion blocking air flow from the TED. a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 17. b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then replace the TED and continue to Step 17. 17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer. Section 4 SECTION 4 (Seat Shuts Off After More Than 40 Seconds) 1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected seat when a heating cycle is initiated. a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2. b. If the TEDs both increase temperature, then proceed to Step 3. 2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED that does not increase temperature from Step 1. a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed to Step 3. b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED, verify the fix and proceed to Step 6. 3. Check for any kinks or obstructions of the ducting from the fan to the TED. a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible otherwise replace the ducting and continue to Step 4. b. If there are no kinks or obstructions of the ducting, then continue to Step 5. 4. If CCS continues to be inoperable with DTC B272C/D code and Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10727 a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 5. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion alignment is incorrect. a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6. b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6. c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 6. d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a climate control seat, then replace the TED and continue to Step 6. 6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer. Section 5 SECTION 5 (Spread Terminal Fix Procedure) 1. Position the front passenger seat fully rearward and up. 2. Pull out and remove the seat track front cover. 3. Disconnect Connector C3265B 24-pin gray. (Figure 3). 4. Remove the red secondary wedge inside the connector. 5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3). NOTE DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG CAVITY. 6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the terminal) and bend the spring into the proper position (Figure 10). 7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the connector. 8. Reconnect C3265B to the dual climate control seat module. 9. Reinstall the seat track front cover. 10. Repower the SRS. Refer to WSM, Section 501-20B. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10728 11. Verify the climate control seat function, and recheck DTCs. 12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D Technical Service Bulletin # 06-13-6 Date: 060710 A/C - Climate Controlled Seats DTC B272C or B272D TSB 06-13-6 07/10/06 DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-14-10 to update the Service Procedure. ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs) B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various sources, making them difficult to diagnose. ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT061306 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14C724 42 Disclaimer Section 1 SECTION 1 1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General Procedures; Supplemental Restraint System Depowering and Repowering. 2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a, C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10734 3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS fails when activated in the heat mode. a. If the time to failure is 5 seconds or less then, proceed to Section 2. b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section 3. c. If the time to failure is 40 seconds or greater, then, proceed to Section 4. NOTE THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4 THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED. THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK. Section 2 SECTION 2 (Seat Shuts Off In Less Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system. a. If there is an over-temp DTC present then go to Step 3. b. If no over-temp DTC is present then go to Step 6. 3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go to Step 4. b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11. c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair as needed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10735 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger cushion) Figure 1.) a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM. b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms? (1) If no, then replace TED. (2) If yes, go to Step 5. 5. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then go to Step 6. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to Step 12. b. If not then proceed to Step 7. 7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then proceed to Step 8. b. If no, then go to Step 9 in Section 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10736 8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) a. If plugged in, then proceed to Step 9. b. If not plugged in, then correct and proceed to Step 12. 9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM). (Figure 2) a. If it is open, then proceed to Step 10. b. If it is not open, then proceed to Step 11. 10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the harnesses). a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step 12. b. If the wire harnesses are good, then proceed to Step 11. 11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms (proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room temperature)? a. No, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. Yes, then replace the DCCSM and proceed to Step 12. 12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to customer. Section 3 SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B). a. If there is an over-temp DTC present, then continue to Step 3. b. If there is no over-temp DTC present, then continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10737 c. If CCS is now operable, then repower the SRS and return vehicle to customer. 3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If readings are hotter than room temperature, go to Step 4. b. If TED temperatures between Back and Cushion are 100 different, go to Step 12. c. If reading correctly then, proceed to Step 5. 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion). (Figure 1) a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on. (1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground. (2) If yes, fix the wiring, if no replace the DCCSM. b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms? (1) If yes, go to Step 5. (2) If no, then replace TED. (Figure 2) 5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, go to Step 6. b. If no, go to Step 7. 6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to Pin 2. a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM, otherwise replace the harness. Verify system now functions and return vehicle to customer. b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system now functions and return vehicle to customer. 7. Cycle ignition and enter into high cool mode. Does failure still occur? a. If no, proceed to Step 8. b. If yes, proceed to Step 13. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10738 8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED connector. NOTE DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE a. If voltage is not getting to the suspect TED, proceed to Step 9. b. If voltage is getting to the suspect TED, replace TED. 9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the module. (Figure 3) ^ Driver Cushion - Pin 9 ^ Driver Backrest - Pin 8 ^ Passenger Cushion - Pin 11 ^ Passenger Backrest - Pin 22 a. If no voltage is coming out of the module, then replace the module and continue to Step 13. b. If the correct voltage is coming out of the module, then continue to Step 10. 10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found, then continue to Step 11. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10739 11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2 volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5) 12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms (proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room temperature)? a. If no, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. If yes, then proceed to Step 13. 13. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1. b. Time to failure is not different than before, then continue to Step 14. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10740 14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7) a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10741 b. If there are no kinks or obstructions of the ducting then, continue to Step 16. 15. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 16. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10742 16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been obstructed or damaged or bunched in the cushion blocking air flow from the TED. a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 17. b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then replace the TED and continue to Step 17. 17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer. Section 4 SECTION 4 (Seat Shuts Off After More Than 40 Seconds) 1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected seat when a heating cycle is initiated. a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2. b. If the TEDs both increase temperature, then proceed to Step 3. 2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED that does not increase temperature from Step 1. a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed to Step 3. b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED, verify the fix and proceed to Step 6. 3. Check for any kinks or obstructions of the ducting from the fan to the TED. a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible otherwise replace the ducting and continue to Step 4. b. If there are no kinks or obstructions of the ducting, then continue to Step 5. 4. If CCS continues to be inoperable with DTC B272C/D code and Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10743 a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 5. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion alignment is incorrect. a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6. b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6. c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 6. d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a climate control seat, then replace the TED and continue to Step 6. 6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer. Section 5 SECTION 5 (Spread Terminal Fix Procedure) 1. Position the front passenger seat fully rearward and up. 2. Pull out and remove the seat track front cover. 3. Disconnect Connector C3265B 24-pin gray. (Figure 3). 4. Remove the red secondary wedge inside the connector. 5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3). NOTE DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG CAVITY. 6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the terminal) and bend the spring into the proper position (Figure 10). 7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the connector. 8. Reconnect C3265B to the dual climate control seat module. 9. Reinstall the seat track front cover. 10. Repower the SRS. Refer to WSM, Section 501-20B. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10744 11. Verify the climate control seat function, and recheck DTCs. 12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D Technical Service Bulletin # 06-13-6 Date: 060710 A/C - Climate Controlled Seats DTC B272C or B272D TSB 06-13-6 07/10/06 DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-14-10 to update the Service Procedure. ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs) B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various sources, making them difficult to diagnose. ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT061306 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14C724 42 Disclaimer Section 1 SECTION 1 1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General Procedures; Supplemental Restraint System Depowering and Repowering. 2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a, C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10753 3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS fails when activated in the heat mode. a. If the time to failure is 5 seconds or less then, proceed to Section 2. b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section 3. c. If the time to failure is 40 seconds or greater, then, proceed to Section 4. NOTE THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4 THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED. THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK. Section 2 SECTION 2 (Seat Shuts Off In Less Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system. a. If there is an over-temp DTC present then go to Step 3. b. If no over-temp DTC is present then go to Step 6. 3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go to Step 4. b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11. c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair as needed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10754 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger cushion) Figure 1.) a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM. b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms? (1) If no, then replace TED. (2) If yes, go to Step 5. 5. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then go to Step 6. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to Step 12. b. If not then proceed to Step 7. 7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then proceed to Step 8. b. If no, then go to Step 9 in Section 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10755 8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) a. If plugged in, then proceed to Step 9. b. If not plugged in, then correct and proceed to Step 12. 9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM). (Figure 2) a. If it is open, then proceed to Step 10. b. If it is not open, then proceed to Step 11. 10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the harnesses). a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step 12. b. If the wire harnesses are good, then proceed to Step 11. 11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms (proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room temperature)? a. No, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. Yes, then replace the DCCSM and proceed to Step 12. 12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to customer. Section 3 SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B). a. If there is an over-temp DTC present, then continue to Step 3. b. If there is no over-temp DTC present, then continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10756 c. If CCS is now operable, then repower the SRS and return vehicle to customer. 3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If readings are hotter than room temperature, go to Step 4. b. If TED temperatures between Back and Cushion are 100 different, go to Step 12. c. If reading correctly then, proceed to Step 5. 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion). (Figure 1) a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on. (1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground. (2) If yes, fix the wiring, if no replace the DCCSM. b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms? (1) If yes, go to Step 5. (2) If no, then replace TED. (Figure 2) 5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, go to Step 6. b. If no, go to Step 7. 6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to Pin 2. a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM, otherwise replace the harness. Verify system now functions and return vehicle to customer. b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system now functions and return vehicle to customer. 7. Cycle ignition and enter into high cool mode. Does failure still occur? a. If no, proceed to Step 8. b. If yes, proceed to Step 13. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10757 8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED connector. NOTE DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE a. If voltage is not getting to the suspect TED, proceed to Step 9. b. If voltage is getting to the suspect TED, replace TED. 9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the module. (Figure 3) ^ Driver Cushion - Pin 9 ^ Driver Backrest - Pin 8 ^ Passenger Cushion - Pin 11 ^ Passenger Backrest - Pin 22 a. If no voltage is coming out of the module, then replace the module and continue to Step 13. b. If the correct voltage is coming out of the module, then continue to Step 10. 10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found, then continue to Step 11. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10758 11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2 volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5) 12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms (proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room temperature)? a. If no, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. If yes, then proceed to Step 13. 13. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1. b. Time to failure is not different than before, then continue to Step 14. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10759 14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7) a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10760 b. If there are no kinks or obstructions of the ducting then, continue to Step 16. 15. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 16. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10761 16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been obstructed or damaged or bunched in the cushion blocking air flow from the TED. a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 17. b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then replace the TED and continue to Step 17. 17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer. Section 4 SECTION 4 (Seat Shuts Off After More Than 40 Seconds) 1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected seat when a heating cycle is initiated. a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2. b. If the TEDs both increase temperature, then proceed to Step 3. 2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED that does not increase temperature from Step 1. a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed to Step 3. b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED, verify the fix and proceed to Step 6. 3. Check for any kinks or obstructions of the ducting from the fan to the TED. a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible otherwise replace the ducting and continue to Step 4. b. If there are no kinks or obstructions of the ducting, then continue to Step 5. 4. If CCS continues to be inoperable with DTC B272C/D code and Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10762 a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 5. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion alignment is incorrect. a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6. b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6. c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 6. d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a climate control seat, then replace the TED and continue to Step 6. 6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer. Section 5 SECTION 5 (Spread Terminal Fix Procedure) 1. Position the front passenger seat fully rearward and up. 2. Pull out and remove the seat track front cover. 3. Disconnect Connector C3265B 24-pin gray. (Figure 3). 4. Remove the red secondary wedge inside the connector. 5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3). NOTE DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG CAVITY. 6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the terminal) and bend the spring into the proper position (Figure 10). 7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the connector. 8. Reconnect C3265B to the dual climate control seat module. 9. Reinstall the seat track front cover. 10. Repower the SRS. Refer to WSM, Section 501-20B. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10763 11. Verify the climate control seat function, and recheck DTCs. 12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-21-3 > Oct > 08 > A/C - Inoperative/Blows Warm Air Compressor Pulley: All Technical Service Bulletins A/C - Inoperative/Blows Warm Air TSB 08-21-3 10/27/08 A/C SYSTEM BLOWS WARM/INOPERATIVE - HIGH AMBIENT TEMPERATURES, EXTENDED IDLE TIMES, TRAILER TOW, DUSTY CLIMATES OR OFF ROAD USE FORD: 2006 Expedition LINCOLN: 2006 Navigator ISSUE Some 2006 Expedition and Navigator vehicles equipped with A/C may become inoperative or blow warm air due to an open electrical circuit of the A/C compressor field coil in high ambient temperatures, extended idle times, trailer tow, dusty climates or off road use. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Replace the A/C clutch disc, field coil and compressor pulley, using the part numbers below. The replacing parts are larger in diameter. Failure to use the part numbers listed below together may cause repeat failure. 1. Recover A/C refrigerant per Workshop Manual (WSM), Section 412-00. 2. Replace the A/C compressor clutch, field coil and pulley per WSM, Section 412-01. 3. Recharge A/C system per WSM, Section 412-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082103A 2006 Expedition 4X2, 1.4 Hrs. Navigator 4X2/4X4: Replace the A/C compressor clutch, field coil and pulley, Includes Time To Remove and Install Compressor (Do Not Use With 19700A, 19700A4) 082103A 2006 Expedition 4X4: 1.6 Hrs. Replace the A/C compressor clutch, field coil and pulley, Includes Time To Remove and Install Compressor (Do Not Use With 19700A, 19700A4) DEALER CODING CONDITION BASIC PART NO. CODE 19D798 28 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-21-3 > Oct > 08 > A/C - Inoperative/Blows Warm Air > Page 10769 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Switch: > 08-21-3 > Oct > 08 > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D Technical Service Bulletin # 06-13-6 Date: 060710 A/C - Climate Controlled Seats DTC B272C or B272D TSB 06-13-6 07/10/06 DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-14-10 to update the Service Procedure. ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs) B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various sources, making them difficult to diagnose. ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT061306 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14C724 42 Disclaimer Section 1 SECTION 1 1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General Procedures; Supplemental Restraint System Depowering and Repowering. 2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a, C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Switch: > 08-21-3 > Oct > 08 > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10779 3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS fails when activated in the heat mode. a. If the time to failure is 5 seconds or less then, proceed to Section 2. b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section 3. c. If the time to failure is 40 seconds or greater, then, proceed to Section 4. NOTE THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4 THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED. THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK. Section 2 SECTION 2 (Seat Shuts Off In Less Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system. a. If there is an over-temp DTC present then go to Step 3. b. If no over-temp DTC is present then go to Step 6. 3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go to Step 4. b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11. c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair as needed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Switch: > 08-21-3 > Oct > 08 > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10780 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger cushion) Figure 1.) a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM. b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms? (1) If no, then replace TED. (2) If yes, go to Step 5. 5. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then go to Step 6. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to Step 12. b. If not then proceed to Step 7. 7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then proceed to Step 8. b. If no, then go to Step 9 in Section 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Switch: > 08-21-3 > Oct > 08 > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10781 8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) a. If plugged in, then proceed to Step 9. b. If not plugged in, then correct and proceed to Step 12. 9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM). (Figure 2) a. If it is open, then proceed to Step 10. b. If it is not open, then proceed to Step 11. 10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the harnesses). a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step 12. b. If the wire harnesses are good, then proceed to Step 11. 11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms (proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room temperature)? a. No, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. Yes, then replace the DCCSM and proceed to Step 12. 12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to customer. Section 3 SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B). a. If there is an over-temp DTC present, then continue to Step 3. b. If there is no over-temp DTC present, then continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Switch: > 08-21-3 > Oct > 08 > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10782 c. If CCS is now operable, then repower the SRS and return vehicle to customer. 3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If readings are hotter than room temperature, go to Step 4. b. If TED temperatures between Back and Cushion are 100 different, go to Step 12. c. If reading correctly then, proceed to Step 5. 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion). (Figure 1) a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on. (1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground. (2) If yes, fix the wiring, if no replace the DCCSM. b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms? (1) If yes, go to Step 5. (2) If no, then replace TED. (Figure 2) 5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, go to Step 6. b. If no, go to Step 7. 6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to Pin 2. a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM, otherwise replace the harness. Verify system now functions and return vehicle to customer. b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system now functions and return vehicle to customer. 7. Cycle ignition and enter into high cool mode. Does failure still occur? a. If no, proceed to Step 8. b. If yes, proceed to Step 13. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Switch: > 08-21-3 > Oct > 08 > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10783 8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED connector. NOTE DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE a. If voltage is not getting to the suspect TED, proceed to Step 9. b. If voltage is getting to the suspect TED, replace TED. 9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the module. (Figure 3) ^ Driver Cushion - Pin 9 ^ Driver Backrest - Pin 8 ^ Passenger Cushion - Pin 11 ^ Passenger Backrest - Pin 22 a. If no voltage is coming out of the module, then replace the module and continue to Step 13. b. If the correct voltage is coming out of the module, then continue to Step 10. 10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found, then continue to Step 11. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Switch: > 08-21-3 > Oct > 08 > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10784 11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2 volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5) 12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms (proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room temperature)? a. If no, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. If yes, then proceed to Step 13. 13. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1. b. Time to failure is not different than before, then continue to Step 14. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Switch: > 08-21-3 > Oct > 08 > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10785 14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7) a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Switch: > 08-21-3 > Oct > 08 > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10786 b. If there are no kinks or obstructions of the ducting then, continue to Step 16. 15. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 16. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Switch: > 08-21-3 > Oct > 08 > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10787 16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been obstructed or damaged or bunched in the cushion blocking air flow from the TED. a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 17. b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then replace the TED and continue to Step 17. 17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer. Section 4 SECTION 4 (Seat Shuts Off After More Than 40 Seconds) 1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected seat when a heating cycle is initiated. a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2. b. If the TEDs both increase temperature, then proceed to Step 3. 2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED that does not increase temperature from Step 1. a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed to Step 3. b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED, verify the fix and proceed to Step 6. 3. Check for any kinks or obstructions of the ducting from the fan to the TED. a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible otherwise replace the ducting and continue to Step 4. b. If there are no kinks or obstructions of the ducting, then continue to Step 5. 4. If CCS continues to be inoperable with DTC B272C/D code and Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Switch: > 08-21-3 > Oct > 08 > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10788 a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 5. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion alignment is incorrect. a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6. b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6. c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 6. d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a climate control seat, then replace the TED and continue to Step 6. 6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer. Section 5 SECTION 5 (Spread Terminal Fix Procedure) 1. Position the front passenger seat fully rearward and up. 2. Pull out and remove the seat track front cover. 3. Disconnect Connector C3265B 24-pin gray. (Figure 3). 4. Remove the red secondary wedge inside the connector. 5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3). NOTE DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG CAVITY. 6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the terminal) and bend the spring into the proper position (Figure 10). 7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the connector. 8. Reconnect C3265B to the dual climate control seat module. 9. Reinstall the seat track front cover. 10. Repower the SRS. Refer to WSM, Section 501-20B. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Heater Switch: > 08-21-3 > Oct > 08 > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10789 11. Verify the climate control seat function, and recheck DTCs. 12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor Pulley: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D Technical Service Bulletin # 06-13-6 Date: 060710 A/C - Climate Controlled Seats DTC B272C or B272D TSB 06-13-6 07/10/06 DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-14-10 to update the Service Procedure. ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs) B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various sources, making them difficult to diagnose. ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT061306 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14C724 42 Disclaimer Section 1 SECTION 1 1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General Procedures; Supplemental Restraint System Depowering and Repowering. 2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a, C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor Pulley: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10795 3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS fails when activated in the heat mode. a. If the time to failure is 5 seconds or less then, proceed to Section 2. b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section 3. c. If the time to failure is 40 seconds or greater, then, proceed to Section 4. NOTE THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4 THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED. THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK. Section 2 SECTION 2 (Seat Shuts Off In Less Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system. a. If there is an over-temp DTC present then go to Step 3. b. If no over-temp DTC is present then go to Step 6. 3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go to Step 4. b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11. c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair as needed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor Pulley: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10796 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger cushion) Figure 1.) a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM. b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms? (1) If no, then replace TED. (2) If yes, go to Step 5. 5. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then go to Step 6. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to Step 12. b. If not then proceed to Step 7. 7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then proceed to Step 8. b. If no, then go to Step 9 in Section 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor Pulley: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10797 8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) a. If plugged in, then proceed to Step 9. b. If not plugged in, then correct and proceed to Step 12. 9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM). (Figure 2) a. If it is open, then proceed to Step 10. b. If it is not open, then proceed to Step 11. 10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the harnesses). a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step 12. b. If the wire harnesses are good, then proceed to Step 11. 11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms (proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room temperature)? a. No, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. Yes, then replace the DCCSM and proceed to Step 12. 12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to customer. Section 3 SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B). a. If there is an over-temp DTC present, then continue to Step 3. b. If there is no over-temp DTC present, then continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor Pulley: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10798 c. If CCS is now operable, then repower the SRS and return vehicle to customer. 3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If readings are hotter than room temperature, go to Step 4. b. If TED temperatures between Back and Cushion are 100 different, go to Step 12. c. If reading correctly then, proceed to Step 5. 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion). (Figure 1) a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on. (1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground. (2) If yes, fix the wiring, if no replace the DCCSM. b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms? (1) If yes, go to Step 5. (2) If no, then replace TED. (Figure 2) 5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, go to Step 6. b. If no, go to Step 7. 6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to Pin 2. a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM, otherwise replace the harness. Verify system now functions and return vehicle to customer. b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system now functions and return vehicle to customer. 7. Cycle ignition and enter into high cool mode. Does failure still occur? a. If no, proceed to Step 8. b. If yes, proceed to Step 13. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor Pulley: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10799 8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED connector. NOTE DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE a. If voltage is not getting to the suspect TED, proceed to Step 9. b. If voltage is getting to the suspect TED, replace TED. 9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the module. (Figure 3) ^ Driver Cushion - Pin 9 ^ Driver Backrest - Pin 8 ^ Passenger Cushion - Pin 11 ^ Passenger Backrest - Pin 22 a. If no voltage is coming out of the module, then replace the module and continue to Step 13. b. If the correct voltage is coming out of the module, then continue to Step 10. 10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found, then continue to Step 11. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor Pulley: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10800 11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2 volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5) 12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms (proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room temperature)? a. If no, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. If yes, then proceed to Step 13. 13. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1. b. Time to failure is not different than before, then continue to Step 14. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor Pulley: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10801 14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7) a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor Pulley: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10802 b. If there are no kinks or obstructions of the ducting then, continue to Step 16. 15. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 16. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor Pulley: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10803 16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been obstructed or damaged or bunched in the cushion blocking air flow from the TED. a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 17. b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then replace the TED and continue to Step 17. 17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer. Section 4 SECTION 4 (Seat Shuts Off After More Than 40 Seconds) 1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected seat when a heating cycle is initiated. a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2. b. If the TEDs both increase temperature, then proceed to Step 3. 2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED that does not increase temperature from Step 1. a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed to Step 3. b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED, verify the fix and proceed to Step 6. 3. Check for any kinks or obstructions of the ducting from the fan to the TED. a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible otherwise replace the ducting and continue to Step 4. b. If there are no kinks or obstructions of the ducting, then continue to Step 5. 4. If CCS continues to be inoperable with DTC B272C/D code and Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor Pulley: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10804 a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 5. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion alignment is incorrect. a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6. b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6. c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 6. d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a climate control seat, then replace the TED and continue to Step 6. 6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer. Section 5 SECTION 5 (Spread Terminal Fix Procedure) 1. Position the front passenger seat fully rearward and up. 2. Pull out and remove the seat track front cover. 3. Disconnect Connector C3265B 24-pin gray. (Figure 3). 4. Remove the red secondary wedge inside the connector. 5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3). NOTE DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG CAVITY. 6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the terminal) and bend the spring into the proper position (Figure 10). 7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the connector. 8. Reconnect C3265B to the dual climate control seat module. 9. Reinstall the seat track front cover. 10. Repower the SRS. Refer to WSM, Section 501-20B. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor Pulley: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10805 11. Verify the climate control seat function, and recheck DTCs. 12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Thermostat: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D Technical Service Bulletin # 06-13-6 Date: 060710 A/C - Climate Controlled Seats DTC B272C or B272D TSB 06-13-6 07/10/06 DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-14-10 to update the Service Procedure. ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs) B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various sources, making them difficult to diagnose. ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT061306 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14C724 42 Disclaimer Section 1 SECTION 1 1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General Procedures; Supplemental Restraint System Depowering and Repowering. 2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a, C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Thermostat: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10814 3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS fails when activated in the heat mode. a. If the time to failure is 5 seconds or less then, proceed to Section 2. b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section 3. c. If the time to failure is 40 seconds or greater, then, proceed to Section 4. NOTE THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4 THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED. THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK. Section 2 SECTION 2 (Seat Shuts Off In Less Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system. a. If there is an over-temp DTC present then go to Step 3. b. If no over-temp DTC is present then go to Step 6. 3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go to Step 4. b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11. c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair as needed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Thermostat: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10815 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger cushion) Figure 1.) a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM. b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms? (1) If no, then replace TED. (2) If yes, go to Step 5. 5. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then go to Step 6. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to Step 12. b. If not then proceed to Step 7. 7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then proceed to Step 8. b. If no, then go to Step 9 in Section 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Thermostat: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10816 8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) a. If plugged in, then proceed to Step 9. b. If not plugged in, then correct and proceed to Step 12. 9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM). (Figure 2) a. If it is open, then proceed to Step 10. b. If it is not open, then proceed to Step 11. 10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the harnesses). a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step 12. b. If the wire harnesses are good, then proceed to Step 11. 11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms (proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room temperature)? a. No, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. Yes, then replace the DCCSM and proceed to Step 12. 12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to customer. Section 3 SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B). a. If there is an over-temp DTC present, then continue to Step 3. b. If there is no over-temp DTC present, then continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Thermostat: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10817 c. If CCS is now operable, then repower the SRS and return vehicle to customer. 3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If readings are hotter than room temperature, go to Step 4. b. If TED temperatures between Back and Cushion are 100 different, go to Step 12. c. If reading correctly then, proceed to Step 5. 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion). (Figure 1) a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on. (1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground. (2) If yes, fix the wiring, if no replace the DCCSM. b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms? (1) If yes, go to Step 5. (2) If no, then replace TED. (Figure 2) 5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, go to Step 6. b. If no, go to Step 7. 6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to Pin 2. a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM, otherwise replace the harness. Verify system now functions and return vehicle to customer. b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system now functions and return vehicle to customer. 7. Cycle ignition and enter into high cool mode. Does failure still occur? a. If no, proceed to Step 8. b. If yes, proceed to Step 13. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Thermostat: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10818 8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED connector. NOTE DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE a. If voltage is not getting to the suspect TED, proceed to Step 9. b. If voltage is getting to the suspect TED, replace TED. 9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the module. (Figure 3) ^ Driver Cushion - Pin 9 ^ Driver Backrest - Pin 8 ^ Passenger Cushion - Pin 11 ^ Passenger Backrest - Pin 22 a. If no voltage is coming out of the module, then replace the module and continue to Step 13. b. If the correct voltage is coming out of the module, then continue to Step 10. 10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found, then continue to Step 11. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Thermostat: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10819 11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2 volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5) 12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms (proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room temperature)? a. If no, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. If yes, then proceed to Step 13. 13. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1. b. Time to failure is not different than before, then continue to Step 14. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Thermostat: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10820 14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7) a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Thermostat: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10821 b. If there are no kinks or obstructions of the ducting then, continue to Step 16. 15. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 16. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Thermostat: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10822 16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been obstructed or damaged or bunched in the cushion blocking air flow from the TED. a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 17. b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then replace the TED and continue to Step 17. 17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer. Section 4 SECTION 4 (Seat Shuts Off After More Than 40 Seconds) 1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected seat when a heating cycle is initiated. a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2. b. If the TEDs both increase temperature, then proceed to Step 3. 2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED that does not increase temperature from Step 1. a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed to Step 3. b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED, verify the fix and proceed to Step 6. 3. Check for any kinks or obstructions of the ducting from the fan to the TED. a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible otherwise replace the ducting and continue to Step 4. b. If there are no kinks or obstructions of the ducting, then continue to Step 5. 4. If CCS continues to be inoperable with DTC B272C/D code and Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Thermostat: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10823 a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 5. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion alignment is incorrect. a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6. b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6. c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 6. d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a climate control seat, then replace the TED and continue to Step 6. 6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer. Section 5 SECTION 5 (Spread Terminal Fix Procedure) 1. Position the front passenger seat fully rearward and up. 2. Pull out and remove the seat track front cover. 3. Disconnect Connector C3265B 24-pin gray. (Figure 3). 4. Remove the red secondary wedge inside the connector. 5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3). NOTE DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG CAVITY. 6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the terminal) and bend the spring into the proper position (Figure 10). 7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the connector. 8. Reconnect C3265B to the dual climate control seat module. 9. Reinstall the seat track front cover. 10. Repower the SRS. Refer to WSM, Section 501-20B. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Thermostat: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10824 11. Verify the climate control seat function, and recheck DTCs. 12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Thermostat: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D Technical Service Bulletin # 06-13-6 Date: 060710 A/C - Climate Controlled Seats DTC B272C or B272D TSB 06-13-6 07/10/06 DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-14-10 to update the Service Procedure. ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs) B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various sources, making them difficult to diagnose. ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT061306 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14C724 42 Disclaimer Section 1 SECTION 1 1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General Procedures; Supplemental Restraint System Depowering and Repowering. 2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a, C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Thermostat: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10830 3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS fails when activated in the heat mode. a. If the time to failure is 5 seconds or less then, proceed to Section 2. b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section 3. c. If the time to failure is 40 seconds or greater, then, proceed to Section 4. NOTE THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4 THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED. THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK. Section 2 SECTION 2 (Seat Shuts Off In Less Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system. a. If there is an over-temp DTC present then go to Step 3. b. If no over-temp DTC is present then go to Step 6. 3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go to Step 4. b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11. c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair as needed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Thermostat: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10831 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger cushion) Figure 1.) a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM. b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms? (1) If no, then replace TED. (2) If yes, go to Step 5. 5. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then go to Step 6. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to Step 12. b. If not then proceed to Step 7. 7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then proceed to Step 8. b. If no, then go to Step 9 in Section 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Thermostat: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10832 8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) a. If plugged in, then proceed to Step 9. b. If not plugged in, then correct and proceed to Step 12. 9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM). (Figure 2) a. If it is open, then proceed to Step 10. b. If it is not open, then proceed to Step 11. 10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the harnesses). a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step 12. b. If the wire harnesses are good, then proceed to Step 11. 11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms (proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room temperature)? a. No, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. Yes, then replace the DCCSM and proceed to Step 12. 12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to customer. Section 3 SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B). a. If there is an over-temp DTC present, then continue to Step 3. b. If there is no over-temp DTC present, then continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Thermostat: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10833 c. If CCS is now operable, then repower the SRS and return vehicle to customer. 3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If readings are hotter than room temperature, go to Step 4. b. If TED temperatures between Back and Cushion are 100 different, go to Step 12. c. If reading correctly then, proceed to Step 5. 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion). (Figure 1) a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on. (1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground. (2) If yes, fix the wiring, if no replace the DCCSM. b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms? (1) If yes, go to Step 5. (2) If no, then replace TED. (Figure 2) 5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, go to Step 6. b. If no, go to Step 7. 6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to Pin 2. a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM, otherwise replace the harness. Verify system now functions and return vehicle to customer. b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system now functions and return vehicle to customer. 7. Cycle ignition and enter into high cool mode. Does failure still occur? a. If no, proceed to Step 8. b. If yes, proceed to Step 13. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Thermostat: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10834 8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED connector. NOTE DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE a. If voltage is not getting to the suspect TED, proceed to Step 9. b. If voltage is getting to the suspect TED, replace TED. 9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the module. (Figure 3) ^ Driver Cushion - Pin 9 ^ Driver Backrest - Pin 8 ^ Passenger Cushion - Pin 11 ^ Passenger Backrest - Pin 22 a. If no voltage is coming out of the module, then replace the module and continue to Step 13. b. If the correct voltage is coming out of the module, then continue to Step 10. 10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found, then continue to Step 11. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Thermostat: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10835 11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2 volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5) 12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms (proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room temperature)? a. If no, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. If yes, then proceed to Step 13. 13. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1. b. Time to failure is not different than before, then continue to Step 14. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Thermostat: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10836 14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7) a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Thermostat: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10837 b. If there are no kinks or obstructions of the ducting then, continue to Step 16. 15. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 16. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Thermostat: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10838 16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been obstructed or damaged or bunched in the cushion blocking air flow from the TED. a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 17. b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then replace the TED and continue to Step 17. 17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer. Section 4 SECTION 4 (Seat Shuts Off After More Than 40 Seconds) 1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected seat when a heating cycle is initiated. a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2. b. If the TEDs both increase temperature, then proceed to Step 3. 2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED that does not increase temperature from Step 1. a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed to Step 3. b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED, verify the fix and proceed to Step 6. 3. Check for any kinks or obstructions of the ducting from the fan to the TED. a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible otherwise replace the ducting and continue to Step 4. b. If there are no kinks or obstructions of the ducting, then continue to Step 5. 4. If CCS continues to be inoperable with DTC B272C/D code and Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Thermostat: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10839 a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 5. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion alignment is incorrect. a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6. b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6. c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 6. d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a climate control seat, then replace the TED and continue to Step 6. 6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer. Section 5 SECTION 5 (Spread Terminal Fix Procedure) 1. Position the front passenger seat fully rearward and up. 2. Pull out and remove the seat track front cover. 3. Disconnect Connector C3265B 24-pin gray. (Figure 3). 4. Remove the red secondary wedge inside the connector. 5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3). NOTE DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG CAVITY. 6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the terminal) and bend the spring into the proper position (Figure 10). 7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the connector. 8. Reconnect C3265B to the dual climate control seat module. 9. Reinstall the seat track front cover. 10. Repower the SRS. Refer to WSM, Section 501-20B. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Thermostat: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10840 11. Verify the climate control seat function, and recheck DTCs. 12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Power Seat Track: Service and Repair Seat Track - Power SEAT TRACK - POWER Removal WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Inboard and outboard seat tracks 1. Position the seat to gain access to all seat track-to-floor fasteners. 2. Depower the SRS. 3. Remove the 40 percent seat. 4. Remove the assist spring. Driver seat 5. NOTE: The SRS seat position sensor is serviced with the driver inboard seat track. Disconnect the SRS seat position sensor. Inboard seat track 6. Pull to remove the forward/reverse power seat motor inboard drive cable from inboard seat track. 7. Disconnect the safety belt buckle pretensioner and usage detection electrical connectors. 8. Remove the safety belt buckle pretensioner. - Remove the nut. - Remove the safety belt buckle and pretensioner. 9. Remove the 4 cushion frame-to-inboard seat track nuts. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Power > Page 10845 10. Remove the cushion frame-to-inboard seat track bolt and the inboard seat track. Outboard seat track 11. Pull to remove the forward/reverse power seat motor outboard drive cable from the outboard seat track. 6-way power seat 12. Disconnect the seat control switch electrical connector. 13. Remove the recliner handle screw cover, screw and recliner handle. 14. CAUTION: Use care when removing the lumbar knob. Using both hands, pull with even pressure on both sides of the knob to remove. Remove the manual lumbar knob. 15. Remove the cushion side shield screw from under the manual lumbar knob. 16. CAUTION: Use care not to scratch the side shield when removing the power seat knob. Pry the seat control switch knob off. 17. Access and remove the front cushion side shield screw. 18. Pull to release the center and rear retainers and remove the cushion side shield. 8-way power seat 19. Pry to remove the power recline and seat control switch knobs. 20. Access and remove the cushion side shield front screw. 21. Pull out from the bottom and rear side of the cushion side shield to release the 3 retainer clips. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Power > Page 10846 22. Disconnect the power lumbar and seat control switch electrical connectors and remove the cushion side shield. Outboard seat track 23. Remove the 4 outboard seat track nuts and the outboard seat track. Installation Outboard seat track 1. Position the outboard seat track and install the 4 nuts. - Tighten to 35 Nm (26 lb-ft). 8-way power seat 2. Position the cushion side shield and connect the power lumbar and seat control switch electrical connectors. 3. Push to install the 3 cushion side shield retainers onto the seat frame. 4. Access and install the cushion side shield front screw. 5. Install the power recline and seat control switch knobs. 6-way power seat 6. Position the cushion side shield and install the center and rear retainers into the seat frame. 7. Install the cushion side shield front screw. 8. Install the seat control switch knob. 9. Install the cushion side shield screw from under the manual lumbar knob. 10. Align and install the manual lumbar knob. 11. Position the recliner handle and install the screw and cover. 12. Connect the seat control switch electrical connector. Outboard seat track 13. Install the forward/reverse power seat motor outboard drive cable to the outboard seat track. Inboard seat track 14. Position the inboard seat track to the seat frame and install the cushion frame-to-inboard seat track bolt. - Tighten to 47 Nm (35 lb-ft). 15. Install the 4 cushion frame-to-inboard seat track nuts. - Tighten to 35 Nm (26 lb-ft). 16. Position the safety belt buckle and pretensioner to the bracket and install the nut. - Tighten to 40 Nm (30 lb-ft). 17. Connect the safety belt buckle pretensioner and usage detection electrical connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Power > Page 10847 18. Install the forward/reverse power seat motor inboard drive cable to seat track. Driver seat 19. NOTE: The SRS seat position sensor is serviced with the driver inboard seat track. Connect the SRS seat position sensor. Inboard and outboard seat tracks 20. Install the assist spring. 21. Install the 40 percent seat. 22. Repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Power > Page 10848 Seat Track: Service and Repair Seat Track - Manual SEAT TRACK - MANUAL Removal and Installation WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Position the seat to gain access to all seat track-to-floor fasteners. 2. Depower the SRS. 3. NOTE: 60 percent seat shown, the 40 percent seat similar. Remove the affected seat. 4. Remove recliner handle screw cover. 5. Remove the recliner handle screw and recliner handle. 6. CAUTION: Use care when removing the lumbar knob. Using both hands, pull with even pressure on both sides of the knob to remove. Remove the manual lumbar knob. 7. Remove the screw from the cushion side shield under the lumbar knob. 8. Remove the screw from the front of the cushion side shield. 9. Remove the screw from the back of the cushion side shield. 10. Remove the manual seat track riser and adjust handle. - Remove the 2 outer seat track riser-to-outer seat track nuts. To install, tighten to 43 Nm (32 lb-ft). - Remove the outer seat track riser. - Remove the 3 seat track adjust handle-to-seat track bolts. To install, tighten to 7 Nm (62 lb-in). - Remove the seat track adjust handle. 11. Remove the 4 manual seat track-to-cushion frame bolts and remove the manual seat tracks. - To install, tighten to 24 Nm (18 lb-ft). 12. To install, reverse the removal procedure. 13. Install the affected seat. 14. Repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Vacuum/Pressure Pump, Seats > Vacuum/Pressure Pump Switch, Seats > Component Information > Locations > Lumbar Adjust Switch, Left Front View 151-26 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Vacuum/Pressure Pump, Seats > Vacuum/Pressure Pump Switch, Seats > Component Information > Locations > Lumbar Adjust Switch, Left Front > Page 10854 View 151-27 (Passenger Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Vacuum/Pressure Pump, Seats > Vacuum/Pressure Pump Switch, Seats > Component Information > Diagrams > Lumbar Adjust Switch, Right Front C331 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Vacuum/Pressure Pump, Seats > Vacuum/Pressure Pump Switch, Seats > Component Information > Diagrams > Lumbar Adjust Switch, Right Front > Page 10857 C361 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Vacuum/Pressure Pump, Seats > Vacuum/Pressure Pump Switch, Seats > Component Information > Diagrams > Page 10858 Vacuum/Pressure Pump Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Vacuum/Pressure Pump, Seats > Vacuum/Pressure Pump Switch, Seats > Component Information > Diagrams > Page 10859 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Seats > Vacuum/Pressure Pump, Seats > Vacuum/Pressure Pump Switch, Seats > Component Information > Diagrams > Page 10860 Vacuum/Pressure Pump Switch: Service and Repair LUMBAR CONTROL SWITCH Removal and Installation WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Position the seat to gain access to all seat track-to-floor fasteners. 2. Depower the SRS. 3. Remove the 40 percent seat. 4. Access and remove the cushion side shield front screw. 5. Pull out from the bottom and rear side of cushion side shield to release the 3 retainer clips. 6. Disconnect the power lumbar switch and 8-way power seat switch electrical connectors. 7. Pinch retainer in and push from the rear of power lumbar switch to remove the switch from the side shield. 8. To install, reverse the removal procedure. 9. Install the 40 percent seat. 10. Repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Sensor > Component Information > Diagrams C2090 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations View 151-12 (Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 10868 Pedal Positioning Switch: Diagrams C2089 C2235 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 10869 Pedal Positioning Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 10870 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 10871 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side View 151-29 (Passenger Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side > Page 10876 View 151-28 (Driver Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side Power Door Lock Switch: Diagrams Door Lock Switch, Driver Side C505 C541 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side > Page 10879 Power Door Lock Switch: Diagrams Door Lock Switch, Passenger Side C605 C632 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 10880 Power Door Lock Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 10881 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations View 151-28 (Driver Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 10885 Power Mirror Switch: Diagrams C527 C577 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 10886 Power Mirror Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 10887 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 10888 Power Mirror Switch: Service and Repair EXTERIOR MIRROR CONTROL SWITCH Removal and Installation All vehicles 1. Remove the driver front door trim panel. Navigator 2. Depress the locking tabs and remove the exterior mirror control switch. Expedition Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 10889 3. Remove the exterior mirror control switch. 1 Depress the locking tabs. 2 Remove the exterior mirror control switch. All vehicles 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor View 151-26 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor > Page 10894 View 151-35 (Chassis, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor > Page 10895 View 151-36 (Chassis, Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor > Page 10896 View 151-26 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Driver Memory Seat Recliner Sensor > Page 10897 View 151-26 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor C372 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 10900 C383 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 10901 C373 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 10902 C1151 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 10903 Power Seat Motor Position Sensor: Diagrams C372 C383 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 10904 C373 C1151 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 10905 C1153 C4084 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams > Driver Memory Seat Horizontal Sensor > Page 10906 C3244 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left/Right View 151-21 (Right Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left/Right > Page 10911 View 151-26 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left/Right > Page 10912 View 151-27 (Passenger Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Left Power Seat Switch: Diagrams Left C352 C3016 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Left > Page 10915 Power Seat Switch: Diagrams Right C355 C3026 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Left > Page 10916 C4179 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Left > Page 10917 C4180 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat Power Seat Switch: Testing and Inspection Power Seat Switch, Left-6-Way Power Seat Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10920 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10921 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10922 Power Seat Switch: Testing and Inspection Power Seat Switch, Left-8-Way Power Seat Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10923 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10924 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10925 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10926 Power Seat Switch: Testing and Inspection Power Seat Switch, Right-6-Way Power Seat Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10927 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10928 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10929 Power Seat Switch: Testing and Inspection Power Seat Switch, Right-8-Way Power Seat Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10930 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10931 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10932 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10933 Power Seat Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10934 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10935 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10936 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10937 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10938 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10939 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10940 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10941 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10942 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10943 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10944 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10945 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10946 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10947 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10948 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10949 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left-6-Way Power Seat > Page 10950 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch - 8-Way Power Seat Switch: Service and Repair Seat Control Switch - 8-Way SEAT CONTROL SWITCH - 8-WAY Removal and Installation WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Driver side shown, passenger side similar. 1. Position the seat to gain access to all seat track-to-floor fasteners. 2. Depower the SRS. 3. Remove the 40 percent seat. 4. Pry and remove the seat control switch and power recline knobs. 5. Access and remove the cushion side shield front screw. 6. Pull out from the bottom and rear side of the cushion side shield to release the 3 retainer clips. 7. Disconnect the power lumbar and seat control switch electrical connectors and remove the cushion side shield. 8. Remove the 3 screws and remove the 8-way seat control switch. 9. To install, reverse the removal procedure. 10. Install the 40 percent seat. 11. Repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch - 8-Way > Page 10953 Power Seat Switch: Service and Repair Seat Control Switch - 6-Way SEAT CONTROL SWITCH - 6-WAY Removal and Installation WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Driver seat is shown, passenger is similar. 1. Position the seat to gain access to all seat track-to-floor fasteners. 2. Depower the SRS. 3. Remove the 40 percent seat. 4. From under the seat, disconnect the 6-way power seat switch electrical connector. 5. Remove the recliner handle screw cover, screw and recliner handle. 6. CAUTION: Use care when removing the lumbar knob. Using both hands, pull with even pressure on both sides of the knob to remove. Pull out to remove the manual lumbar knob. 7. Remove the cushion side shield screw from under the manual lumbar knob. 8. CAUTION: Use care not to scratch the side shield when removing the power seat knob. Pry the seat control switch knob off. 9. Access and remove the front cushion side shield screw. 10. Pull to release the center and rear retainers and remove the cushion side shield. 11. Remove the 2 seat control switch screws and remove the 6-way seat control switch from the cushion side shield. 12. To install, reverse the removal procedure. 13. Install the 40 percent seat. 14. Repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch - 8-Way > Page 10954 Power Seat Switch: Service and Repair Seat Control Switch - Third Row SEAT CONTROL SWITCH - THIRD ROW Removal and Installation 1. Partially remove the RH quarter trim panel for access to the third row power seat switch(es.). 2. Remove the one-way push nuts on the back side of the power seat switch bezel. 3. Disconnect the RH and LH third row seat control switch electrical connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch - 8-Way > Page 10955 4. Release the 4 locking tabs (2 shown) on the affected switch, and remove the switch. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations View 151-32 (Liftgate) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Page 10959 C4039 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D Technical Service Bulletin # 06-13-6 Date: 060710 A/C - Climate Controlled Seats DTC B272C or B272D TSB 06-13-6 07/10/06 DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-14-10 to update the Service Procedure. ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs) B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various sources, making them difficult to diagnose. ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT061306 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14C724 42 Disclaimer Section 1 SECTION 1 1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General Procedures; Supplemental Restraint System Depowering and Repowering. 2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a, C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10968 3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS fails when activated in the heat mode. a. If the time to failure is 5 seconds or less then, proceed to Section 2. b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section 3. c. If the time to failure is 40 seconds or greater, then, proceed to Section 4. NOTE THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4 THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED. THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK. Section 2 SECTION 2 (Seat Shuts Off In Less Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system. a. If there is an over-temp DTC present then go to Step 3. b. If no over-temp DTC is present then go to Step 6. 3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go to Step 4. b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11. c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair as needed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10969 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger cushion) Figure 1.) a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM. b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms? (1) If no, then replace TED. (2) If yes, go to Step 5. 5. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then go to Step 6. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to Step 12. b. If not then proceed to Step 7. 7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then proceed to Step 8. b. If no, then go to Step 9 in Section 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10970 8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) a. If plugged in, then proceed to Step 9. b. If not plugged in, then correct and proceed to Step 12. 9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM). (Figure 2) a. If it is open, then proceed to Step 10. b. If it is not open, then proceed to Step 11. 10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the harnesses). a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step 12. b. If the wire harnesses are good, then proceed to Step 11. 11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms (proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room temperature)? a. No, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. Yes, then replace the DCCSM and proceed to Step 12. 12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to customer. Section 3 SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B). a. If there is an over-temp DTC present, then continue to Step 3. b. If there is no over-temp DTC present, then continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10971 c. If CCS is now operable, then repower the SRS and return vehicle to customer. 3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If readings are hotter than room temperature, go to Step 4. b. If TED temperatures between Back and Cushion are 100 different, go to Step 12. c. If reading correctly then, proceed to Step 5. 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion). (Figure 1) a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on. (1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground. (2) If yes, fix the wiring, if no replace the DCCSM. b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms? (1) If yes, go to Step 5. (2) If no, then replace TED. (Figure 2) 5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, go to Step 6. b. If no, go to Step 7. 6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to Pin 2. a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM, otherwise replace the harness. Verify system now functions and return vehicle to customer. b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system now functions and return vehicle to customer. 7. Cycle ignition and enter into high cool mode. Does failure still occur? a. If no, proceed to Step 8. b. If yes, proceed to Step 13. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10972 8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED connector. NOTE DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE a. If voltage is not getting to the suspect TED, proceed to Step 9. b. If voltage is getting to the suspect TED, replace TED. 9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the module. (Figure 3) ^ Driver Cushion - Pin 9 ^ Driver Backrest - Pin 8 ^ Passenger Cushion - Pin 11 ^ Passenger Backrest - Pin 22 a. If no voltage is coming out of the module, then replace the module and continue to Step 13. b. If the correct voltage is coming out of the module, then continue to Step 10. 10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found, then continue to Step 11. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10973 11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2 volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5) 12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms (proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room temperature)? a. If no, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. If yes, then proceed to Step 13. 13. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1. b. Time to failure is not different than before, then continue to Step 14. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10974 14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7) a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10975 b. If there are no kinks or obstructions of the ducting then, continue to Step 16. 15. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 16. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10976 16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been obstructed or damaged or bunched in the cushion blocking air flow from the TED. a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 17. b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then replace the TED and continue to Step 17. 17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer. Section 4 SECTION 4 (Seat Shuts Off After More Than 40 Seconds) 1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected seat when a heating cycle is initiated. a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2. b. If the TEDs both increase temperature, then proceed to Step 3. 2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED that does not increase temperature from Step 1. a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed to Step 3. b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED, verify the fix and proceed to Step 6. 3. Check for any kinks or obstructions of the ducting from the fan to the TED. a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible otherwise replace the ducting and continue to Step 4. b. If there are no kinks or obstructions of the ducting, then continue to Step 5. 4. If CCS continues to be inoperable with DTC B272C/D code and Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10977 a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 5. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion alignment is incorrect. a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6. b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6. c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 6. d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a climate control seat, then replace the TED and continue to Step 6. 6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer. Section 5 SECTION 5 (Spread Terminal Fix Procedure) 1. Position the front passenger seat fully rearward and up. 2. Pull out and remove the seat track front cover. 3. Disconnect Connector C3265B 24-pin gray. (Figure 3). 4. Remove the red secondary wedge inside the connector. 5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3). NOTE DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG CAVITY. 6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the terminal) and bend the spring into the proper position (Figure 10). 7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the connector. 8. Reconnect C3265B to the dual climate control seat module. 9. Reinstall the seat track front cover. 10. Repower the SRS. Refer to WSM, Section 501-20B. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10978 11. Verify the climate control seat function, and recheck DTCs. 12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D Technical Service Bulletin # 06-13-6 Date: 060710 A/C - Climate Controlled Seats DTC B272C or B272D TSB 06-13-6 07/10/06 DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-14-10 to update the Service Procedure. ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs) B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various sources, making them difficult to diagnose. ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT061306 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14C724 42 Disclaimer Section 1 SECTION 1 1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General Procedures; Supplemental Restraint System Depowering and Repowering. 2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a, C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10984 3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS fails when activated in the heat mode. a. If the time to failure is 5 seconds or less then, proceed to Section 2. b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section 3. c. If the time to failure is 40 seconds or greater, then, proceed to Section 4. NOTE THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4 THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED. THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK. Section 2 SECTION 2 (Seat Shuts Off In Less Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system. a. If there is an over-temp DTC present then go to Step 3. b. If no over-temp DTC is present then go to Step 6. 3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go to Step 4. b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11. c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair as needed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10985 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger cushion) Figure 1.) a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM. b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms? (1) If no, then replace TED. (2) If yes, go to Step 5. 5. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then go to Step 6. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to Step 12. b. If not then proceed to Step 7. 7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then proceed to Step 8. b. If no, then go to Step 9 in Section 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10986 8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) a. If plugged in, then proceed to Step 9. b. If not plugged in, then correct and proceed to Step 12. 9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM). (Figure 2) a. If it is open, then proceed to Step 10. b. If it is not open, then proceed to Step 11. 10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the harnesses). a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step 12. b. If the wire harnesses are good, then proceed to Step 11. 11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms (proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room temperature)? a. No, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. Yes, then replace the DCCSM and proceed to Step 12. 12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to customer. Section 3 SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B). a. If there is an over-temp DTC present, then continue to Step 3. b. If there is no over-temp DTC present, then continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10987 c. If CCS is now operable, then repower the SRS and return vehicle to customer. 3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If readings are hotter than room temperature, go to Step 4. b. If TED temperatures between Back and Cushion are 100 different, go to Step 12. c. If reading correctly then, proceed to Step 5. 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion). (Figure 1) a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on. (1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground. (2) If yes, fix the wiring, if no replace the DCCSM. b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms? (1) If yes, go to Step 5. (2) If no, then replace TED. (Figure 2) 5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, go to Step 6. b. If no, go to Step 7. 6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to Pin 2. a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM, otherwise replace the harness. Verify system now functions and return vehicle to customer. b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system now functions and return vehicle to customer. 7. Cycle ignition and enter into high cool mode. Does failure still occur? a. If no, proceed to Step 8. b. If yes, proceed to Step 13. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10988 8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED connector. NOTE DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE a. If voltage is not getting to the suspect TED, proceed to Step 9. b. If voltage is getting to the suspect TED, replace TED. 9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the module. (Figure 3) ^ Driver Cushion - Pin 9 ^ Driver Backrest - Pin 8 ^ Passenger Cushion - Pin 11 ^ Passenger Backrest - Pin 22 a. If no voltage is coming out of the module, then replace the module and continue to Step 13. b. If the correct voltage is coming out of the module, then continue to Step 10. 10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found, then continue to Step 11. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10989 11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2 volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5) 12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms (proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room temperature)? a. If no, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. If yes, then proceed to Step 13. 13. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1. b. Time to failure is not different than before, then continue to Step 14. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10990 14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7) a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10991 b. If there are no kinks or obstructions of the ducting then, continue to Step 16. 15. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 16. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10992 16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been obstructed or damaged or bunched in the cushion blocking air flow from the TED. a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 17. b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then replace the TED and continue to Step 17. 17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer. Section 4 SECTION 4 (Seat Shuts Off After More Than 40 Seconds) 1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected seat when a heating cycle is initiated. a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2. b. If the TEDs both increase temperature, then proceed to Step 3. 2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED that does not increase temperature from Step 1. a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed to Step 3. b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED, verify the fix and proceed to Step 6. 3. Check for any kinks or obstructions of the ducting from the fan to the TED. a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible otherwise replace the ducting and continue to Step 4. b. If there are no kinks or obstructions of the ducting, then continue to Step 5. 4. If CCS continues to be inoperable with DTC B272C/D code and Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10993 a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 5. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion alignment is incorrect. a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6. b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6. c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 6. d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a climate control seat, then replace the TED and continue to Step 6. 6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer. Section 5 SECTION 5 (Spread Terminal Fix Procedure) 1. Position the front passenger seat fully rearward and up. 2. Pull out and remove the seat track front cover. 3. Disconnect Connector C3265B 24-pin gray. (Figure 3). 4. Remove the red secondary wedge inside the connector. 5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3). NOTE DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG CAVITY. 6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the terminal) and bend the spring into the proper position (Figure 10). 7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the connector. 8. Reconnect C3265B to the dual climate control seat module. 9. Reinstall the seat track front cover. 10. Repower the SRS. Refer to WSM, Section 501-20B. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Sensor: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 10994 11. Verify the climate control seat function, and recheck DTCs. 12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D Technical Service Bulletin # 06-13-6 Date: 060710 A/C - Climate Controlled Seats DTC B272C or B272D TSB 06-13-6 07/10/06 DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-14-10 to update the Service Procedure. ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs) B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various sources, making them difficult to diagnose. ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT061306 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14C724 42 Disclaimer Section 1 SECTION 1 1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General Procedures; Supplemental Restraint System Depowering and Repowering. 2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a, C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 11003 3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS fails when activated in the heat mode. a. If the time to failure is 5 seconds or less then, proceed to Section 2. b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section 3. c. If the time to failure is 40 seconds or greater, then, proceed to Section 4. NOTE THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4 THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED. THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK. Section 2 SECTION 2 (Seat Shuts Off In Less Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system. a. If there is an over-temp DTC present then go to Step 3. b. If no over-temp DTC is present then go to Step 6. 3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go to Step 4. b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11. c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair as needed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 11004 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger cushion) Figure 1.) a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM. b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms? (1) If no, then replace TED. (2) If yes, go to Step 5. 5. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then go to Step 6. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to Step 12. b. If not then proceed to Step 7. 7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then proceed to Step 8. b. If no, then go to Step 9 in Section 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 11005 8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) a. If plugged in, then proceed to Step 9. b. If not plugged in, then correct and proceed to Step 12. 9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM). (Figure 2) a. If it is open, then proceed to Step 10. b. If it is not open, then proceed to Step 11. 10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the harnesses). a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step 12. b. If the wire harnesses are good, then proceed to Step 11. 11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms (proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room temperature)? a. No, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. Yes, then replace the DCCSM and proceed to Step 12. 12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to customer. Section 3 SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B). a. If there is an over-temp DTC present, then continue to Step 3. b. If there is no over-temp DTC present, then continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 11006 c. If CCS is now operable, then repower the SRS and return vehicle to customer. 3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If readings are hotter than room temperature, go to Step 4. b. If TED temperatures between Back and Cushion are 100 different, go to Step 12. c. If reading correctly then, proceed to Step 5. 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion). (Figure 1) a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on. (1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground. (2) If yes, fix the wiring, if no replace the DCCSM. b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms? (1) If yes, go to Step 5. (2) If no, then replace TED. (Figure 2) 5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, go to Step 6. b. If no, go to Step 7. 6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to Pin 2. a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM, otherwise replace the harness. Verify system now functions and return vehicle to customer. b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system now functions and return vehicle to customer. 7. Cycle ignition and enter into high cool mode. Does failure still occur? a. If no, proceed to Step 8. b. If yes, proceed to Step 13. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 11007 8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED connector. NOTE DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE a. If voltage is not getting to the suspect TED, proceed to Step 9. b. If voltage is getting to the suspect TED, replace TED. 9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the module. (Figure 3) ^ Driver Cushion - Pin 9 ^ Driver Backrest - Pin 8 ^ Passenger Cushion - Pin 11 ^ Passenger Backrest - Pin 22 a. If no voltage is coming out of the module, then replace the module and continue to Step 13. b. If the correct voltage is coming out of the module, then continue to Step 10. 10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found, then continue to Step 11. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 11008 11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2 volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5) 12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms (proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room temperature)? a. If no, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. If yes, then proceed to Step 13. 13. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1. b. Time to failure is not different than before, then continue to Step 14. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 11009 14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7) a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 11010 b. If there are no kinks or obstructions of the ducting then, continue to Step 16. 15. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 16. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 11011 16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been obstructed or damaged or bunched in the cushion blocking air flow from the TED. a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 17. b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then replace the TED and continue to Step 17. 17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer. Section 4 SECTION 4 (Seat Shuts Off After More Than 40 Seconds) 1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected seat when a heating cycle is initiated. a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2. b. If the TEDs both increase temperature, then proceed to Step 3. 2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED that does not increase temperature from Step 1. a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed to Step 3. b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED, verify the fix and proceed to Step 6. 3. Check for any kinks or obstructions of the ducting from the fan to the TED. a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible otherwise replace the ducting and continue to Step 4. b. If there are no kinks or obstructions of the ducting, then continue to Step 5. 4. If CCS continues to be inoperable with DTC B272C/D code and Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 11012 a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 5. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion alignment is incorrect. a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6. b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6. c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 6. d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a climate control seat, then replace the TED and continue to Step 6. 6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer. Section 5 SECTION 5 (Spread Terminal Fix Procedure) 1. Position the front passenger seat fully rearward and up. 2. Pull out and remove the seat track front cover. 3. Disconnect Connector C3265B 24-pin gray. (Figure 3). 4. Remove the red secondary wedge inside the connector. 5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3). NOTE DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG CAVITY. 6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the terminal) and bend the spring into the proper position (Figure 10). 7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the connector. 8. Reconnect C3265B to the dual climate control seat module. 9. Reinstall the seat track front cover. 10. Repower the SRS. Refer to WSM, Section 501-20B. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 11013 11. Verify the climate control seat function, and recheck DTCs. 12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D Technical Service Bulletin # 06-13-6 Date: 060710 A/C - Climate Controlled Seats DTC B272C or B272D TSB 06-13-6 07/10/06 DTC B272-C/D FOR THE DUAL CLIMATE CONTROL SEAT MODULE FORD: 2005-2006 Expedition LINCOLN: 2005-2006 Navigator This article supersedes TSB 05-14-10 to update the Service Procedure. ISSUE Some 2005-2006 Expedition and Navigator vehicles built prior to 03/26/2006 may exhibit concerns with the climate controlled seat (CCS) system with diagnostic trouble codes (DTCs) B272C (Driver Differential Temperature Fault) and/or DTC B272D (Passenger Differential Temperature Fault), with or without additional DTCs. These two DTCs may be triggered by various sources, making them difficult to diagnose. ACTION Refer to the following Service Procedure to isolate the cause of these DTCs. If DTC B272C and/or B272D are not present, follow normal Workshop Manual (WSM) diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT061306 Claim Labor As Actual Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 14C724 42 Disclaimer Section 1 SECTION 1 1. Depower the supplemental restraint system (SRS). Refer to WSM, Section 501-20B, General Procedures; Supplemental Restraint System Depowering and Repowering. 2. Check the connections along the CCS systems, passenger side: C3040, C3039, C3625a, C3625b; driver side: C3034, C3035, C311, C316, C3625b, C3625a. Ensure connectors are fully seated and secure. If the CCS is now operable, repower the SRS and return vehicle to the customer. If CCS system is still inoperable leave SRS depowered, continue to Step 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 11019 3. If CCS continues to be inoperable with a DTC of B272C/D code then note the time until the CCS fails when activated in the heat mode. a. If the time to failure is 5 seconds or less then, proceed to Section 2. b. If the time to failure is greater than 5 seconds but less than 40 seconds then, proceed to Section 3. c. If the time to failure is 40 seconds or greater, then, proceed to Section 4. NOTE THERE ARE 4 PIDS WHEN USING IDS THAT READ THE TEMPERATURE OF THE 4 THERMO-ELECTRIC DEVICES (TEDS) IN THE VEHICLE. WHEN ASKED TO MONITOR THE PIDS, THIS TSB IS REFERRING TO THE PID'S OF THE AFFECTED SEAT BEING DIAGNOSED. THE PIDS ARE AS FOLLOWS: (CSHTEMP) DRIVER CUSHION, (BK_TEMP) DRIVER SEAT BACK, (PCSHTMP) PASSENGER CUSHION, (PBK_TEMP) PASSENGER SEAT BACK. Section 2 SECTION 2 (Seat Shuts Off In Less Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS is inoperable with a DTC B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B) only on the first heating cycle. If the over-temp code is present after several heating cycles then allow the TED's to rest for 15 minutes before retesting the system. a. If there is an over-temp DTC present then go to Step 3. b. If no over-temp DTC is present then go to Step 6. 3. Are any of the TED PIDS reading between 200-400° F (93-204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If reading excessively hotter than room temperature, for example 200° F (93° C) or so, then go to Step 4. b. If TED temperatures between Back TED and Cushion TED are 10° different, go to Step 11. c. If readings are correct, then check for blockage / obstruction of the cushion or the ducting. If blockage is not found, then replace the module and proceed to Step 5. If blockage is found, repair as needed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 11020 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - driver back, C3035 - driver cushion, C3039 - passenger back, or C3040 - passenger cushion) Figure 1.) a. Check harness side of TED Connector (C3034 - driver back, C3035 - driver cushion, C3039 passenger back, or C3040 - passenger cushion) for voltage with IGN on; is approximately 5v +/1.5v present at Pin 3. If voltage is present, proceed to Step 4b. If not, then unplug the dual climate control seat module (DCCSM) located under the passenger seat, and check if harness side Pin 3 is shorted to ground. If Pin 3 is shorted fix wiring, if not replace DCCSM. b. Check TED assembly connector, is resistance across Pins 2 and 3 greater than 200 ohms? (1) If no, then replace TED. (2) If yes, go to Step 5. 5. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then go to Step 6. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 6. Are both ambient TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then the Connector C32656 on the DCCSM is not plugged in, or both TEDs (Driver C3034 and C3035, Passenger - C3039 and C3040) are not plugged in. Plug it in and proceed to Step 12. b. If not then proceed to Step 7. 7. Is one of the TED PID readings below 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, then proceed to Step 8. b. If no, then go to Step 9 in Section 3. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 11021 8. Verify the TED is plugged in. (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) a. If plugged in, then proceed to Step 9. b. If not plugged in, then correct and proceed to Step 12. 9. Is the thermistor circuit in the TED open? (Check the connector (C3034 - Driver Back C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion, C3265A - DCCSM). (Figure 2) a. If it is open, then proceed to Step 10. b. If it is not open, then proceed to Step 11. 10. Verify the wire harnesses to the thermistor are good (looking for shorts or opens in the harnesses). a. If the wire harnesses to the thermistor are not good, then repair as needed and proceed to Step 12. b. If the wire harnesses are good, then proceed to Step 11. 11. Is the resistance on the thermistor circuit at the TED Connector (C3034 - Driver Back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) (between 2.7 K ohms (proper value at 65° F) (18° C) to 1.86 K ohms (proper value at 80° F) (27° C) at ambient (room temperature)? a. No, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. Yes, then replace the DCCSM and proceed to Step 12. 12. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1, otherwise repower the SRS and finish other repairs as needed and return vehicle to customer. Section 3 SECTION 3 (Seat Shuts Off Less Than 40 Seconds, But More Than 5 Seconds) 1. Follow the spread terminal fix procedure listed in Section 5. If this has already been performed and in Step 3 in Section 1 has lead you back to this procedure, proceed to Step 2. 2. If CCS continues to be inoperable with a B272C/D code, determine if an over-temp DTC is present (B2729, B2730, B272A, B272B). a. If there is an over-temp DTC present, then continue to Step 3. b. If there is no over-temp DTC present, then continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 11022 c. If CCS is now operable, then repower the SRS and return vehicle to customer. 3. Are any of the Temperature PIDS reading between 200° F (93° C) and 400° F (204° C) at room temperature conditions (when heat mode has not been on for 5 minutes), or is one TED reading 10° higher than the other TED? a. If readings are hotter than room temperature, go to Step 4. b. If TED temperatures between Back and Cushion are 100 different, go to Step 12. c. If reading correctly then, proceed to Step 5. 4. Check for short to ground or voltage in the thermistor circuit. (As shown on TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion). (Figure 1) a. Looking into the harness side of the TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should read 5v +/1.5v present at Pin 3 with the ignition on. (1) If no, then unplug DCCSM and check if harness side Pin 3 is shorted to ground. (2) If yes, fix the wiring, if no replace the DCCSM. b. Checking TED assembly connector, is resistance across Pins 2 and 3 greater than 1000 ohms? (1) If yes, go to Step 5. (2) If no, then replace TED. (Figure 2) 5. Is one of the TED PID readings less than 0° F (-18° C) or greater than 400° F (204° C)? a. If yes, go to Step 6. b. If no, go to Step 7. 6. Ensure the module is producing voltage to the thermistor circuit of the TED, checking the harness side of TED connector (C3034 - Driver Back, C3035 - Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) the voltage should be 5v +/- 1.5v present at Pin 3 with ref to Pin 2. a. If no voltage to thermistor is present at TED, then ensure the harness is not damaged by checking the voltage at the module Connector C3265A-Pins 13, 14, 15, 16 (DCCSM Connector C3265B must remain plugged in). If no voltage is present at DCCSM, then replace DCCSM, otherwise replace the harness. Verify system now functions and return vehicle to customer. b. If the correct voltage is present to the thermistor, then replace the TED assembly. Verify system now functions and return vehicle to customer. 7. Cycle ignition and enter into high cool mode. Does failure still occur? a. If no, proceed to Step 8. b. If yes, proceed to Step 13. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 11023 8. Ensure voltage is getting to the suspect TED. Enter heat mode and back probe Pin 6 of the TED connector. NOTE DO NOT LEAVE IN HEAT MODE FOR OVER 1 MINUTE a. If voltage is not getting to the suspect TED, proceed to Step 9. b. If voltage is getting to the suspect TED, replace TED. 9. Ensure voltage is coming out of the module by back probing the suspect pin on C3265B of the module. (Figure 3) ^ Driver Cushion - Pin 9 ^ Driver Backrest - Pin 8 ^ Passenger Cushion - Pin 11 ^ Passenger Backrest - Pin 22 a. If no voltage is coming out of the module, then replace the module and continue to Step 13. b. If the correct voltage is coming out of the module, then continue to Step 10. 10. Disconnect DCCSM C3265B. Check for an open circuit (resistance greater than 5 ohms) from the TED that is reading the cold temperature to the CCSM (C3265B). If no open circuit is found, then continue to Step 11. (Figure 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 11024 11. With DCCSM C3265B disconnected, check for a short circuit (short to voltage is less than 0.2 volts, short to ground is resistance less than 10,000 ohms) in the wiring from the TED that is not reading the over-temp to the CCSM. If no short circuit is found, then replace the TED. (Figure 5) 12. Is the resistance on the thermistor circuit at the TED connector (C3034 - driver back, C3035 Driver Cushion, C3039 - Passenger Back, or C3040 - Passenger Cushion) between 2.7 K ohms (proper value @ 65° F) (18° C) to 1.86 K ohms (proper value @ 80° F) (27° C) at ambient (room temperature)? a. If no, then replace the TED that is outside the resistance range specified above, assuming the TED is at room temperature, and proceed to Step 12. b. If yes, then proceed to Step 13. 13. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 4 Section 1. b. Time to failure is not different than before, then continue to Step 14. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 11025 14. Check for any kinks or obstructions of the ducting from the fan to the TED. (Figures 6 and 7) a. If there is a kink or obstruction of the ducting, repair as needed and continue to Step 15. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 11026 b. If there are no kinks or obstructions of the ducting then, continue to Step 16. 15. If CCS continues to be inoperable with a B272C/D code and: a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 16. c. If CCS is now operable, then repower the SRS and finish other repairs as needed and return vehicle to customer. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 11027 16. Check if the seat back/cushions are damaged or the scrim (Figures 8 and 9) has been obstructed or damaged or bunched in the cushion blocking air flow from the TED. a. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 17. b. If the cushion or scrim is not damaged or bunched and is correct for a climate control seat, then replace the TED and continue to Step 17. 17. If CCS continues to be inoperable with DTC B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB. If CCS in now operable, repower the SRS, and return vehicle to customer. Section 4 SECTION 4 (Seat Shuts Off After More Than 40 Seconds) 1. Check the temperature PIDS with a generic scan tool (GST) from the two TEDs on the affected seat when a heating cycle is initiated. a. If a TED does not increase more than 1 or 2 degrees, then proceed to Step 2. b. If the TEDs both increase temperature, then proceed to Step 3. 2. Let the TEDs sit with no heating or cooling cycle for 5 minutes. Check the resistance of the TED that does not increase temperature from Step 1. a. If the resistance of the TED is around 2.5 ohms +/- 10 ohms at room temperature, then proceed to Step 3. b. If the resistance of the TED is 0 or hundreds of ohms at room temperature then replace the TED, verify the fix and proceed to Step 6. 3. Check for any kinks or obstructions of the ducting from the fan to the TED. a. If there are kinks, then replace the ducting, if there is an obstruction, then remove if possible otherwise replace the ducting and continue to Step 4. b. If there are no kinks or obstructions of the ducting, then continue to Step 5. 4. If CCS continues to be inoperable with DTC B272C/D code and Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 11028 a. Time to failure is different than before, then start new diagnosis from Step 3 in Section 1. b. Time to failure is not different than before, then continue to Step 5. c. If CCS is now operable, then repower the SRS and return vehicle to customer. 5. Check for seat back/cushions damage or if the scrim (Figures 9 and 10) has been obstructed or damaged or bunched in the cushion blocking airflow from the TED, or the TED - CCS cushion alignment is incorrect. a. If the cushion is not a CCS cushion, then replace it with a CCS cushion and proceed to Step 6. b. If the TED and cushion alignment are incorrect, then correct the alignment, proceed to Step 6. c. If the cushion or scrim is damaged or bunched or is incorrect, then repair or replace the damaged cushion/scrim and continue to Step 6. d. If the cushion or scrim is not damaged or bunched and the cushion is a correct cushion for a climate control seat, then replace the TED and continue to Step 6. 6. If CCS continues to be inoperable with a B272C/D code, start a new diagnosis from Step 3 in Section 1 of this TSB; otherwise repower the SRS and return vehicle to customer. Section 5 SECTION 5 (Spread Terminal Fix Procedure) 1. Position the front passenger seat fully rearward and up. 2. Pull out and remove the seat track front cover. 3. Disconnect Connector C3265B 24-pin gray. (Figure 3). 4. Remove the red secondary wedge inside the connector. 5. Using an appropriate pick, or equivalent, disengage the internal lock that holds the terminals in cavities 8, 9, 10, 11, 21, 22, 23, 24 (Figure 3). NOTE DO NOT DISENGAGE MORE THAN ONE (1) CIRCUIT AT A TIME. ONLY DISENGAGE THE NEXT CIRCUIT AFTER THE PREVIOUS ONE HAS BEEN REPAIRED AND REASSEMBLED INTO THE CONNECTOR. THIS WILL PREVENT INSERTING CIRCUITS INTO THE WRONG CAVITY. 6. Insert the dental pick into the back part of each terminal (inside the box-shaped portion of the terminal) and bend the spring into the proper position (Figure 10). 7. After all eight (8) terminals have been repaired, reinsert the red secondary wedge into the connector. 8. Reconnect C3265B to the dual climate control seat module. 9. Reinstall the seat track front cover. 10. Repower the SRS. Refer to WSM, Section 501-20B. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Switch: > 06-13-6 > Jul > 06 > A/C - Climate Controlled Seats DTC B272C or B272D > Page 11029 11. Verify the climate control seat function, and recheck DTCs. 12. If CCS continues to be inoperable with DTC B272C/D, start a new diagnosis from Step 3 in Section 1. If no DTCs are present, and system is operating correctly, repower the SRS, and return vehicle to customer. If system is still not operating properly, follow normal diagnostics per WSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations View 151-28 (Driver Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 11033 C503 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 11034 Seat Memory Switch: Testing and Inspection SWITCH - MEMORY SET Memory Set Switch Remove the memory set switch. Measure the resistance between the indicated terminals while pressing the requested switches. The resistance should be less than 5 ohms for each switch position. If the resistance is not less than 5 ohms for each switch, install a new switch; otherwise, return to the calling pinpoint test. NOTE: Refer to multimeter user's manual for testing diodes. To check the memory set switch LED, connect the positive meter lead to terminal 7 and the negative lead to terminal 1. 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, install a new switch; otherwise, return to the calling pinpoint test. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations View 151-23 (Roof) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 11038 Sunroof / Moonroof Switch: Diagrams C912 C9001 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 11039 Sunroof / Moonroof Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 11040 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Liftgate Fork Bolt/Detent Switch View 151-32 (Liftgate) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Liftgate Fork Bolt/Detent Switch > Page 11045 View 151-32 (Liftgate) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Liftgate Fork Bolt/Detent Switch > Page 11046 View 151-23 (Roof) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Liftgate Fork Bolt/Detent Switch C4190 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Liftgate Fork Bolt/Detent Switch > Page 11049 C4187 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Liftgate Fork Bolt/Detent Switch > Page 11050 C9000 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump Switch, Seats > Component Information > Locations > Lumbar Adjust Switch, Left Front View 151-26 (Driver Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump Switch, Seats > Component Information > Locations > Lumbar Adjust Switch, Left Front > Page 11055 View 151-27 (Passenger Seat) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump Switch, Seats > Component Information > Diagrams > Lumbar Adjust Switch, Right Front C331 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump Switch, Seats > Component Information > Diagrams > Lumbar Adjust Switch, Right Front > Page 11058 C361 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump Switch, Seats > Component Information > Diagrams > Page 11059 Vacuum/Pressure Pump Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump Switch, Seats > Component Information > Diagrams > Page 11060 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Vacuum/Pressure Pump Switch, Seats > Component Information > Diagrams > Page 11061 Vacuum/Pressure Pump Switch: Service and Repair LUMBAR CONTROL SWITCH Removal and Installation WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Position the seat to gain access to all seat track-to-floor fasteners. 2. Depower the SRS. 3. Remove the 40 percent seat. 4. Access and remove the cushion side shield front screw. 5. Pull out from the bottom and rear side of cushion side shield to release the 3 retainer clips. 6. Disconnect the power lumbar switch and 8-way power seat switch electrical connectors. 7. Pinch retainer in and push from the rear of power lumbar switch to remove the switch from the side shield. 8. To install, reverse the removal procedure. 9. Install the 40 percent seat. 10. Repower the SRS. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and Operation Sound Proofing / Insulation: Description and Operation INSULATION Insulation is installed: - under the roof. - above and below the instrument panel. - at the cowl sides. - over the transmission tunnel. - over the floorpan areas. - inside the quarter panels. And has heat-bondable mastic deadeners for improved NVH characteristics (Navigator). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL PANEL GRILLE Removal and Installation 1. Remove the windshield wipers. 2. Remove the cowl grille seal. 3. Remove the pin-type retainer and left side cowl trim panel. - Disconnect the windshield washer tube. 4. Remove the right side cowl trim panel. 1 Disconnect the windshield washer tube. 2 Remove the pin-type retainer. 5. If necessary, adjust the windshield wiper arms. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body Sunroof Water Leaks During High Pressure Car Wash Sunroof / Moonroof Weatherstrip: Customer Interest Body - Sunroof Water Leaks During High Pressure Car Wash TSB 08-24-8 12/08/08 WATER LEAKS - ROOF OPENING PANEL DURING HIGH PRESSURE CAR WASH FORD: 2005-2008 F-150, F-250, F-350, F-450, F-550 2005-2009 Expedition LINCOLN: 2005-2009 Navigator 2006-2008 Mark LT This article supersedes TSB 08-1-4 to update the Part List and Service procedure. ISSUE Some 2005-2009 Expedition, Navigator, 2005-2008 F-150, F-Super Duty and 2006-2008 Mark LT vehicles with factory installed roof opening panel may experience a water leak at the rear of roof opening panel during a high pressure car wash. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2005-2008 F-150 / F-Super Duty 250-550 / 2006-2008 Mark LT 1. Remove roof opening panel glass only. Refer to Work Shop Manual (WSM), Section 501-17. 2. To avoid paint damage to the roof, apply protective covering on roof finish. 3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from the trough guide assembly. 4. With rear trough removed; wipe clean the top inside of the trough with an alcohol based cleaner or equivalent. 5. Remove the adhesive tape covering from trough seal. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body Sunroof Water Leaks During High Pressure Car Wash > Page 11079 6. Attach seal to front of trough starting at one end of the trough. Make sure the vertical leg of seal lines up against front flange of trough. (Figures 1-3) 7. Secure seal across entire trough. Apply pressure along entire seal to ensure bonding to trough. 8. Install the rear trough onto the trough guide assembly. Install the two (2) trough guide retaining screws and torque to 9 lb-in. (1 N.m) 9. Remove protective covering. 10. Install roof opening panel following WSM, Section 501-17. 2005-2009 Expedition / Navigator 1. Remove roof opening panel glass only. Refer to WSM, Section 501-17. 2. To avoid paint damage to the roof, apply protective covering on roof finish. 3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from the trough guide assembly. 4. Install new trough and seal assembly. 5. Install the rear trough and seal assembly onto the trough guide assembly. Install the two (2) trough guide retaining screws and torque to 9 lb-in. (1 N.m) 6. Remove protective covering. 7. Install roof opening panel following WSM, Section 501-17. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body Sunroof Water Leaks During High Pressure Car Wash > Page 11080 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082408A 2005-2009 Expedition, 0.5 Hr. Navigator: Follow The Service Procedure To Repair The Water leak (Do Not Use With 5028A) 082408A 2005-2008 F-Super Duty, 0.6 Hr. F-150, 2005-2008 Mark LT: Follow The Service Procedure To Repair The Water leak (Do Not Use With 5028A) DEALER CODING CONDITION BASIC PART NO. CODE 78502C50 07 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash Sunroof / Moonroof Weatherstrip: All Technical Service Bulletins Body - Sunroof Water Leaks During High Pressure Car Wash TSB 08-24-8 12/08/08 WATER LEAKS - ROOF OPENING PANEL DURING HIGH PRESSURE CAR WASH FORD: 2005-2008 F-150, F-250, F-350, F-450, F-550 2005-2009 Expedition LINCOLN: 2005-2009 Navigator 2006-2008 Mark LT This article supersedes TSB 08-1-4 to update the Part List and Service procedure. ISSUE Some 2005-2009 Expedition, Navigator, 2005-2008 F-150, F-Super Duty and 2006-2008 Mark LT vehicles with factory installed roof opening panel may experience a water leak at the rear of roof opening panel during a high pressure car wash. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2005-2008 F-150 / F-Super Duty 250-550 / 2006-2008 Mark LT 1. Remove roof opening panel glass only. Refer to Work Shop Manual (WSM), Section 501-17. 2. To avoid paint damage to the roof, apply protective covering on roof finish. 3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from the trough guide assembly. 4. With rear trough removed; wipe clean the top inside of the trough with an alcohol based cleaner or equivalent. 5. Remove the adhesive tape covering from trough seal. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash > Page 11086 6. Attach seal to front of trough starting at one end of the trough. Make sure the vertical leg of seal lines up against front flange of trough. (Figures 1-3) 7. Secure seal across entire trough. Apply pressure along entire seal to ensure bonding to trough. 8. Install the rear trough onto the trough guide assembly. Install the two (2) trough guide retaining screws and torque to 9 lb-in. (1 N.m) 9. Remove protective covering. 10. Install roof opening panel following WSM, Section 501-17. 2005-2009 Expedition / Navigator 1. Remove roof opening panel glass only. Refer to WSM, Section 501-17. 2. To avoid paint damage to the roof, apply protective covering on roof finish. 3. From above vehicle, remove the two (2) trough guide retaining screws and the rear trough from the trough guide assembly. 4. Install new trough and seal assembly. 5. Install the rear trough and seal assembly onto the trough guide assembly. Install the two (2) trough guide retaining screws and torque to 9 lb-in. (1 N.m) 6. Remove protective covering. 7. Install roof opening panel following WSM, Section 501-17. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 08-24-8 > Dec > 08 > Body - Sunroof Water Leaks During High Pressure Car Wash > Page 11087 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082408A 2005-2009 Expedition, 0.5 Hr. Navigator: Follow The Service Procedure To Repair The Water leak (Do Not Use With 5028A) 082408A 2005-2008 F-Super Duty, 0.6 Hr. F-150, 2005-2008 Mark LT: Follow The Service Procedure To Repair The Water leak (Do Not Use With 5028A) DEALER CODING CONDITION BASIC PART NO. CODE 78502C50 07 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Page 11088 Sunroof / Moonroof Weatherstrip: Service and Repair ROOF OPENING PANEL WEATHERSTRIP Removal NOTE: The roof opening panel must be initialized when repairs are carried out on any part of the roof opening panel, including: whenever the roof opening panel has been removed from the roof opening panel assembly, a new roof opening panel motor/module has been installed or when a new roof opening panel assembly has been installed. 1. Remove the roof opening panel. 2. Place roof opening panel, topside up, on a worktable. Take care to support the glass assembly from below to prevent damaging the mounting tabs. 3. Remove the old roof opening panel weatherstrip by pulling up on the weatherstrip. Installation 1. Place a new weatherstrip into position on the glass assembly, with the splice (seam) on the passenger side. 2. Starting with the corners, push the weatherstrip into position. Continue pushing the weatherstrip into position around the glass assembly until complete. Use a plastic or rubber hammer if necessary. 3. Install the roof opening panel. 4. Adjust the roof panel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch View 151-1 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch > Page 11094 View 151-10 (behind Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch C277 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch > Page 11097 C278 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Brake Pedal Position (BPP) Switch Brake Switch (Cruise Control): Description and Operation Brake Pedal Position (BPP) Switch BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - BPP switch is hardwired to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - BPP switch is hardwired to the Anti-Lock Brake System (ABS) Module, Lighting Control Module (LCM), or Rear Electronic Module (REM), the BPP signal is then broadcast over the network to be received by the PCM. - BPP switch is hardwired to the anti-lock brake system (ABS) traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Brake Pedal Position (BPP) Switch > Page 11100 Brake Switch (Cruise Control): Description and Operation Brake Pedal Switch (BPS)/Brake Deactivator Switch BRAKE PEDAL SWITCH (BPS)/BRAKE DEACTIVATOR SWITCH The BPS, also called the brake deactivator switch, is for vehicle speed control deactivation. A normally closed switch supplies battery positive voltage (B+) to the PCM when the brake pedal is not applied. When the brake pedal is applied, the normally closed switch opens and power is removed from the PCM. On some applications the normally closed BPS, along with the normally open BPP switch, are used for a brake rationality test within the PCM. The PCM misfire monitor profile learn function may be disabled if a brake switch concern occurs. If one or both brake pedal inputs to the PCM is not changing states when they were expected to, a diagnostic trouble code is set by the PCM strategy. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Page 11101 Brake Switch (Cruise Control): Service and Repair SPEED CONTROL DEACTIVATOR SWITCH Removal 1. NOTE: The speed control deactivator switch can only be adjusted once. If further adjusting is necessary, install a new switch. Remove the speed control deactivator switch. 1 Disconnect the electrical connector. 2 Rotate the deactivator switch counterclockwise 45 degrees and remove the switch. Installation All vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Page 11102 1. Release the plunger lock (if equipped). - Turn the lock knob counterclockwise until the first click is felt. 2. Fully apply the brake pedal 3. Install the speed control deactivator switch. 1 Position the deactivator switch in the bracket and rotate it clockwise 45 degrees. 2 Connect the electrical connector. Vehicles equipped with a locking tab 4. NOTE: There should be an extra click heard when tugging on the brake pedal. Slowly release the brake pedal and tug it moderately once the pedal reaches the rest position. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Description and Operation Clutch Switch: Description and Operation CLUTCH PEDAL POSITION (CPP) SWITCH Typical Clutch Pedal Position (CPP) Switch The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine load. The PCM uses the load information for mass air flow and fuel calculations. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair Cruise Control Switch: Service and Repair SPEED CONTROL SWITCH Removal and Installation All vehicles 1. Remove the driver air bag module. Expedition 2. Remove the 2 screws and the speed control switch. - Disconnect the electrical connector. Navigator 3. Remove the horn switch. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Page 11109 1 Disconnect the electrical connector. 2 Remove the 4 bolts. 4. Remove the speed control switch. 1 Disconnect the wiring harness locators. 2 Remove the 4 screws. To install, tighten to 7 Nm (62 lb-in). All vehicles 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch View 151-1 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch > Page 11115 View 151-10 (behind Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch C277 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch > Page 11118 C278 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Brake Pedal Position (BPP) Switch Brake Switch (Cruise Control): Description and Operation Brake Pedal Position (BPP) Switch BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - BPP switch is hardwired to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - BPP switch is hardwired to the Anti-Lock Brake System (ABS) Module, Lighting Control Module (LCM), or Rear Electronic Module (REM), the BPP signal is then broadcast over the network to be received by the PCM. - BPP switch is hardwired to the anti-lock brake system (ABS) traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Brake Pedal Position (BPP) Switch > Page 11121 Brake Switch (Cruise Control): Description and Operation Brake Pedal Switch (BPS)/Brake Deactivator Switch BRAKE PEDAL SWITCH (BPS)/BRAKE DEACTIVATOR SWITCH The BPS, also called the brake deactivator switch, is for vehicle speed control deactivation. A normally closed switch supplies battery positive voltage (B+) to the PCM when the brake pedal is not applied. When the brake pedal is applied, the normally closed switch opens and power is removed from the PCM. On some applications the normally closed BPS, along with the normally open BPP switch, are used for a brake rationality test within the PCM. The PCM misfire monitor profile learn function may be disabled if a brake switch concern occurs. If one or both brake pedal inputs to the PCM is not changing states when they were expected to, a diagnostic trouble code is set by the PCM strategy. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Page 11122 Brake Switch (Cruise Control): Service and Repair SPEED CONTROL DEACTIVATOR SWITCH Removal 1. NOTE: The speed control deactivator switch can only be adjusted once. If further adjusting is necessary, install a new switch. Remove the speed control deactivator switch. 1 Disconnect the electrical connector. 2 Rotate the deactivator switch counterclockwise 45 degrees and remove the switch. Installation All vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Page 11123 1. Release the plunger lock (if equipped). - Turn the lock knob counterclockwise until the first click is felt. 2. Fully apply the brake pedal 3. Install the speed control deactivator switch. 1 Position the deactivator switch in the bracket and rotate it clockwise 45 degrees. 2 Connect the electrical connector. Vehicles equipped with a locking tab 4. NOTE: There should be an extra click heard when tugging on the brake pedal. Slowly release the brake pedal and tug it moderately once the pedal reaches the rest position. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Description and Operation Clutch Switch: Description and Operation CLUTCH PEDAL POSITION (CPP) SWITCH Typical Clutch Pedal Position (CPP) Switch The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine load. The PCM uses the load information for mass air flow and fuel calculations. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair Cruise Control Switch: Service and Repair SPEED CONTROL SWITCH Removal and Installation All vehicles 1. Remove the driver air bag module. Expedition 2. Remove the 2 screws and the speed control switch. - Disconnect the electrical connector. Navigator 3. Remove the horn switch. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Page 11130 1 Disconnect the electrical connector. 2 Remove the 4 bolts. 4. Remove the speed control switch. 1 Disconnect the wiring harness locators. 2 Remove the 4 screws. To install, tighten to 7 Nm (62 lb-in). All vehicles 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > Customer Interest for Audible Warning Device: > 05-22-17 > Nov > 05 > Restraints - Cannot Disable 'Belt Minder' Chime Audible Warning Device: Customer Interest Restraints - Cannot Disable 'Belt Minder' Chime TSB 05-22-17 11/14/05 INABILITY TO DISABLE THE SUPPLEMENTAL SAFETY BELT WARNING CHIME (BELTMINDER) FORD: 2006 Expedition LINCOLN: 2006 Navigator ISSUE Some 2006 Expedition/Navigator vehicles may exhibit an inability to disable the Belt Minder function following procedures listed in the Workshop Manual or the Owner Guide. The Belt Minder function operates normally, but can not be turned off (if desired by the customer). ACTION Replace the restraint control module (RCM), which includes software to disable the Belt Minder. Refer to Workshop Manual, Section 501-20B to replace the RCM. Then follow Workshop Manual, Section 413-09 or the Owner Guide procedure to disable the Belt Minder function. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052217A 2006 Expedition: Replace 1.0 Hrs. The Restraints Control Module Includes Time To Depower And Repower The Supplemental Restraints System And Disable The Beltminder (Do Not Use With 14056D, 14056D1B, 14056D1C, 14056D1XN, 14056DZR) 052217A 2006 Navigator: Replace 1.2 Hrs. The Restraints Control Module Includes Time To Depower And Repower The Supplemental Restraints System And Disable The Beltminder (Do Not Use With 14056D, 14056D1B, 14056D1C, 14056D1XN, 14056DZR) DEALER CODING CONDITION BASIC PART NO. CODE 14B321 42 OASIS CODES: 104000, 206000 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > Customer Interest for Audible Warning Device: > 05-22-17 > Nov > 05 > Restraints - Cannot Disable 'Belt Minder' Chime > Page 11140 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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: > 05-22-17 > Nov > 05 > Restraints - Cannot Disable 'Belt Minder' Chime Audible Warning Device: All Technical Service Bulletins Restraints - Cannot Disable 'Belt Minder' Chime TSB 05-22-17 11/14/05 INABILITY TO DISABLE THE SUPPLEMENTAL SAFETY BELT WARNING CHIME (BELTMINDER) FORD: 2006 Expedition LINCOLN: 2006 Navigator ISSUE Some 2006 Expedition/Navigator vehicles may exhibit an inability to disable the Belt Minder function following procedures listed in the Workshop Manual or the Owner Guide. The Belt Minder function operates normally, but can not be turned off (if desired by the customer). ACTION Replace the restraint control module (RCM), which includes software to disable the Belt Minder. Refer to Workshop Manual, Section 501-20B to replace the RCM. Then follow Workshop Manual, Section 413-09 or the Owner Guide procedure to disable the Belt Minder function. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052217A 2006 Expedition: Replace 1.0 Hrs. The Restraints Control Module Includes Time To Depower And Repower The Supplemental Restraints System And Disable The Beltminder (Do Not Use With 14056D, 14056D1B, 14056D1C, 14056D1XN, 14056DZR) 052217A 2006 Navigator: Replace 1.2 Hrs. The Restraints Control Module Includes Time To Depower And Repower The Supplemental Restraints System And Disable The Beltminder (Do Not Use With 14056D, 14056D1B, 14056D1C, 14056D1XN, 14056DZR) DEALER CODING CONDITION BASIC PART NO. CODE 14B321 42 OASIS CODES: 104000, 206000 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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: > 05-22-17 > Nov > 05 > Restraints - Cannot Disable 'Belt Minder' Chime > Page 11146 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > Page 11147 View 151-32 (Liftgate) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > Page 11148 C4186 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11153 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11154 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11155 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11156 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11157 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11158 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11159 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11160 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11161 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11162 Cigarette Lighter: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11163 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11164 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11165 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11166 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11167 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11168 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11169 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11170 C2031 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11171 Cigarette Lighter: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 44-1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11172 44-2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11173 44-3 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. See: Diagrams/Components/Component Location Views Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams C2016 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Page 11177 Clock: Description and Operation CLOCK The stand-alone electric analog clock, available in the Navigator only, is centrally located on the instrument panel and displays time in a 12 hour format. The clock is backlit when the headlamps and parking lamps are on. The Expedition clock is integrated into the radio. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 INSPECTION AND VERIFICATION 1. Verify the customer concern. Visual Inspection Chart 2. Visually inspect for obvious signs of mechanical or electrical damage. 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the fault is not visually evident, verify the symptom and GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11180 Symptom Chart Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11181 Clock: Pinpoint Tests PINPOINT TEST A: THE CLOCK OPERATION IS ERRATIC/INOPERATIVE A1 A1-A2 Normal Operation The clock receives battery voltage from the central junction box (CJB) through circuit 729 (RD/WH). Ground for the clock is supplied through circuit 57 (BK). Possible Causes - fuse - clock - circuit 57 (BK) open - circuit 729 (RD/WH) open Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Page 11182 Clock: Service and Repair CLOCK Removal and Installation 1. Remove the instrument cluster center finish panel. 2. Disconnect the electrical connector. 3. Release the retaining clips and remove the clock from the instrument cluster center finish panel. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Page 11183 73III Automotive Meter Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams C909 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Vehicle Demagnetizing Compass: Service and Repair Vehicle Demagnetizing VEHICLE DEMAGNETIZING CAUTION: During demagnetizing, the demagnetizer coil is pulled toward the vehicle. Place a cloth over the vehicle roof to protect the vehicle surface if contact occurs. Make sure the cloth covers the front third and the entire width of the roof. NOTE: - The demagnetizing process requires the use of a demagnetizing coil commonly used by television service technicians to demagnetize television tubes. - To demagnetize, use a constant circular motion over the vehicle roof. Do not turn off the demagnetizer while sweeping the vehicle roof to prevent remagnetizing ferrous materials contained in the vehicle. - During the demagnetizing process, make sure the phenolic surface of the tool (the side opposite the handle) is closest to the vehicle surface. 1. Demagnetize the front third of the vehicle roof. 1 Turn on the demagnetizer at least 1 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 radius within 30 cm (12 in) while sweeping across the entire surface of the roof closest to the windshield. Continue the circular motion 4 times. 3 After the fourth pass and without stopping, move the demagnetizer at least 1 meter (3 ft) away from the vehicle. 4 Turn the demagnetizer off. 2. NOTE: The demagnetizer must be located over the outside of the windshield no greater than 2.5 cm (1 in). 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. 3. Carry out the Compass Zone Adjustment procedure. Refer to Compass Zone Adjustment - With Message Center or Compass Zone Adjustment Without Message Center. See: Compass Zone Adjustment/With Message Center See: Compass Zone Adjustment/Without Message Center 4. Carry out the Calibration Adjustment procedure. Refer to Compass Calibration - With Message Center or Compass Calibration - Without Message Center. See: Compass Calibration/With Message Center See: Compass Calibration/Without Message Center Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Vehicle Demagnetizing > Page 11189 Compass: Service and Repair Compass Zone Adjustment With Message Center COMPASS ZONE ADJUSTMENT - WITH MESSAGE CENTER 1. NOTE: The compass zone setting is preset from the factory to Zone 8. Determine which magnetic zone you are in for your geographic location. 2. Start the engine. 3. Press the message center switch INFO button until the compass information is displayed. 4. Press and hold the SETUP and RESET buttons until the message center display changes to show the current zone setting. 5. Press the SETUP button repeatedly until the correct zone setting is displayed in the message center. 6. To exit the zone steering mode, and lock in the changes, press and release the RESET button. Without Message Center COMPASS ZONE ADJUSTMENT - WITHOUT MESSAGE CENTER Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Vehicle Demagnetizing > Page 11190 1. NOTE: The compass zone setting is preset from the factory to Zone 8. Determine which magnetic zone you are in for your geographic location. 2. Start the engine. 3. Press the TRIP/RESET button, hold for 6 seconds and release. ZONE appears in the instrument cluster display. 4. Press and release the TRIP/RESET button until the desired zone number appears. 5. When the desired zone number appears in the instrument cluster display, hold the TRIP/RESET button down to set the new zone number. The instrument cluster display returns to the normal mode when the TRIP/RESET button is not pressed for 6 seconds. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Vehicle Demagnetizing > Page 11191 Compass: Service and Repair Compass Calibration With Message Center COMPASS CALIBRATION - WITH MESSAGE CENTER 1. NOTE: For optimum calibration, drive to an open, level location away from large metallic objects or structures. Switch off all non-essential electrical accessories (heated rear window, heater A/C, map lamps, wiper, etc.) and make sure all the doors are closed. Start the vehicle. 2. Press the RESET control button to start the compass calibration function. 3. Slowly drive the vehicle in a circle less than 5 km/h (3 mph) until the CIRCLE SLOWLY TO CALIBRATE display changes to CALIBRATION COMPLETE. It takes up to 5 circles to complete the compass calibration. Without Message Center COMPASS CALIBRATION - WITHOUT MESSAGE CENTER 1. NOTE: For optimum calibration, drive to an open, level location away from large metallic objects or structures. Switch off all non-essential electrical accessories (heated rear window, heater A/C, map lamps, wiper, etc.) and make sure all the doors are closed. Start the vehicle. 2. Enter the compass calibration mode by pressing and holding the TRIP/RESET button for 8 seconds. The instrument cluster then shows CAL. 3. Slowly drive the vehicle in a circle at no more than 5 km/h (3 mph) until CAL turns off in the instrument cluster display (approximately 5 circles). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Depowering and Repowering SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING Depowering Procedure WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the electrical connector on a safety canopy module. Doing so can result in safety canopy deployment. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the RH side of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse 19 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located at the bottom of the hood latch support bracket. The first row side impact sensors (if equipped) are located in the first row doors, behind the door trim panel. The second row side impact sensors (if equipped) are located at or near the base of the C-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install the RCM fuse 19 (10A) to the CJB and close the cover. 4. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11197 Connect the battery ground cable. 5. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a diagnostic tool. Deactivation and Reactivation SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION Special Tool(s) Special Tool(s) Deactivation WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the connectors on the safety canopy module. Doing so can result in safety canopy module deployment. - To reduce the risk of personal injury, do not use any memory saver devices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11198 NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the RH side of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse 19 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located at the bottom of the hood latch support bracket. The first row side impact sensors (if equipped) are located in the first row doors, behind the door trim panel. The second row side impact sensors (if equipped) are located at or near the base of the C-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 7. Remove the 2 steering wheel back cover plugs (1 shown). 8. Remove the 2 driver air bag module bolts (1 shown). Expedition Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11199 9. Remove the driver air bag module. 1 Release the 2 retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector before disconnecting. 2 Release the 2 retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector before disconnecting. 3 Disconnect the horn switch electrical connector. 4 Remove the driver air bag module. Navigator 10. Disconnect the driver air bag module. - Release the 2 tabs on each driver air bag module electrical connector and disconnect them. Label each driver air bag module electrical connector before disconnecting. 11. Release the tab and disconnect the driver air bag module accessories electrical connector at the top of the clockspring and remove the driver air bag module. All vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11200 12. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of the steering column. 13. While pushing in on the 2 glove compartment door tabs, position the glove compartment downward. 14. NOTE: Expedition shown, Navigator similar. Through the glove compartment opening, release the tab and disconnect the passenger air bag module electrical connector. 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Vehicles with safety canopies Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11201 16. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or if it does not remain closed, install a new shoulder safety belt guide cover. Remove the second row passenger side safety belt guide. 1 Release the retaining tab at each side and open the safety belt guide cover. 2 Remove the nut. 3 Remove the second row passenger side safety belt guide. 17. Remove the passenger side C-pillar trim panel. 1 Separate the weather-stripping along the passenger side C-pillar trim panel. 2 Remove the bolt cover and bolt. 3 Pull out to release the retainers and remove the passenger side C-pillar trim panel. 18. Disconnect the passenger side safety canopy electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11202 19. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy electrical connector. 20. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or if it does not remain closed, install a new shoulder safety belt guide cover. Remove the second row driver side safety belt guide. 1 Release the retaining tab at each side and open the safety belt guide cover. 2 Remove the nut. 3 Remove the second row driver side safety belt guide. 21. Remove the driver side C-pillar trim panel. 1 Separate the weather-stripping along the driver side C-pillar trim panel. 2 Remove the bolt cover and bolt. 3 Pull out to release the retainers and remove the driver side C-pillar trim panel. 22. Disconnect the driver side safety canopy electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11203 23. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy electrical connector. All vehicles 24. Install the RCM fuse 19 (10A) to the CJB. 25. Connect the battery ground cable. Reactivation All vehicles 1. Remove the RCM fuse 19 (10A) from the CJB. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles with safety canopies 3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy electrical connector. 4. Connect the driver side safety canopy electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11204 5. WARNING: Anytime the safety canopy module has deployed, the headliner, and all A, B, and C pillar upper trim panels and attaching hardware must be replaced along with any other damaged components and hardware. Failure to do so may result in personal injury in the event of a safety canopy module deployment. Install the driver side C-pillar trim panel. 1 Position the driver side C-pillar trim panel and push in, engaging the retainers. 2 Install the bolt and bolt cover. Tighten to 11 Nm (8 lb-ft). 3 Install the weather-stripping along the driver side C-pillar trim panel. 6. NOTE: - Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or if it does not remain closed, install a new shoulder safety belt guide cover. - Make sure the safety belt is not twisted prior to installation. Install the second row driver side safety belt guide. 1 Position the second row driver side safety belt guide. 2 Install the nut. Tighten to 40 Nm (30 lb-ft). 3 Close the safety belt guide cover. Verify the safety belt retractor operates without excessive effort or binding. 7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11205 8. Connect the passenger side safety canopy electrical connector. 9. WARNING: Anytime the safety canopy module has deployed, the headliner, and all A, B, and C pillar upper trim panels and attaching hardware must be replaced along with any other damaged components and hardware. Failure to do so may result in personal injury in the event of a safety canopy module deployment. Install the passenger C-pillar trim panel. 1 Position the passenger side C-pillar trim panel and push in, engaging the retainers. 2 Install the bolt and bolt cover. Tighten to 11 Nm (8 lb-ft). 3 Install the weather-stripping along the passenger side C-pillar trim panel. 10. NOTE: - Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or if it does not remain closed, install a new shoulder safety belt guide cover. - Make sure the safety belt is not twisted prior to installation. Install the second row passenger side safety belt guide. 1 Position the second row passenger side safety belt guide. 2 Install the nut. Tighten to 40 Nm (30 lb-ft). 3 Close the safety belt guide cover. Verify the safety belt retractor operates without excessive effort or binding. All vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11206 11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. 12. NOTE: Expedition shown, Navigator similar. Connect the passenger air bag module electrical connector. 13. Close the glove compartment. 14. Remove the restraint system diagnostic tools from the clockspring electrical connector at the top of the steering column. Navigator 15. Connect the driver air bag module accessories electrical connector to the connector end at the top of the clockspring. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11207 16. CAUTION: The clockspring electrical connectors are unique and cannot be reversed when connected to the driver air bag module. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Connect the driver air bag module electrical connectors as noted during removal. Position the driver air bag module to the steering wheel. Expedition 17. Position the driver air bag module to the steering wheel. 1 Connect the horn switch electrical connector. 2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when connected to the driver air bag module. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Connect the driver air bag module electrical connectors as noted during removal. 3 Position the driver air bag module to the steering wheel. All vehicles 18. Install the 2 driver air bag module bolts (1 shown). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11208 19. Install the 2 steering wheel back cover plugs (1 shown). 20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse 19 (10A) to the CJB and close the cover. 23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a diagnostic tool. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11209 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure PROVE OUT PROCEDURE Turn the ignition switch from the OFF to the ON position and visually monitor the air bag indicator with all SRS components connected or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an SRS fault is present, the air bag indicator will: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Service and Repair Dimmer Switch: Service and Repair INSTRUMENT PANEL DIMMER SWITCH Removal and Installation 1. Remove the instrument panel finish panel. - Disconnect the electrical connectors. 2. Press the tabs and remove the instrument panel dimmer switch. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear View 151-30 (Left Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 11217 View 151-28 (Driver Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 11218 View 151-29 (Passenger Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 11219 View 151-31 (Right Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 11220 View 151-32 (Liftgate) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch C479 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 11223 C526 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 11224 C602 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 11225 C715 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 11226 C820 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Page 11227 Door Switch: Service and Repair DOOR AJAR SWITCH Removal and Installation 1. Remove the door lock actuator. 2. Release the locking tab and remove the door ajar switch. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Locations View 151-12 (Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Locations > Page 11231 C253 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Locations > Page 11232 Driver/Vehicle Information Display: Description and Operation INFORMATION AND MESSAGE CENTER The message center display is a green vacuum fluorescent, fixed format display. The message center is a 2-line display integrated into the center of the instrument cluster and is controlled by the message center switches. Refer to the Owner's Literature for operating instructions. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 Principles of Operation PRINCIPLES OF OPERATION The message center is a vacuum fluorescent display, part of the instrument cluster. The message center electronic functions use both hardwired, and controller area network (CAN) circuitry to transmit and receive information. As a technician, it is very important to understand: - where the input (command) originates. - all the information (messages) necessary in order for a feature to operate. - which module(s) receive(s) the input or command message. - if the module that received the input (message) controls the output of the feature, or if it outputs a message over the CAN to another module. - which module controls the output of the feature. The message center provides the following features: - information displays - setup displays - warning messages - system check messages The message center information can be selected through a set of 3 buttons: - INFO - SETUP - RESET Information Displays The information displays are non-timed modes. The selected mode remains on until the driver presses a message center button to change the mode or it is overridden by another mode. The information display modes are: odometer - trip odometer - compass - distance to empty (DTE) - average fuel economy Setup Displays The setup displays are timed modes and terminate after a finite interval. The setup display modes are: system check - English/metric units - power liftgate on/off (if equipped) - running board auto in/out (if equipped) - easy exit seat (if equipped) - autolamp delay - language Warning Messages The warning messages are single cycle, non-resettable and repetitive warning messages. The single cycle warning messages are: CHECK SUSPENSION - CHECK COMPASS MODULE - NO RESPONSE COMPASS - ENGINE TEMP DATA - COMPASS DATA ERROR - DOOR SENSOR DATA ERROR - CHARGING SYSTEM DATA ERROR - CHECK PARK ASSIST - CHECK FUEL CAP - LOW WASHER FLUID LEVEL The single cycle warning messages display once whenever the ignition switch is turned to ON or a fault occurs in a system and can be cleared by pressing the RESET button. The repetitive warning messages are: LOW BRAKE FLUID LEVEL - CHECK CHARGING SYSTEM - LOW FUEL LEVEL - LOW OIL PRESSURE Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11235 - CHECK ENGINE TEMPERATURE - TEMPORARY 4x4 HIGH - CHECK ADV/TRAC - CHECK TIRE PRESSURE The repetitive warning messages are displayed at a fixed interval whenever the ignition switch is turned ON or is in the ACC position. To remove a repetitive warning message, press the RESET button. The message only reoccurs after 10 minutes or until the warning condition is corrected. The non-resettable warning messages are: DOOR AJAR - STOP ENGINE SAFELY - REDUCED ENGINE POWER - ENGINE FAILSAFE MODE - PARK ASSIST ON/OFF - TRAIN LF TIRE - TRAIN LR TIRE - TRAIN RF TIRE - TRAIN RR TIRE - TRAIN SPARE TIRE - TIRE TRAINING MODE COMPLETE - TIRES NOT TRAINED - PARK BRAKE ENGAGED The non-resettable warning messages display whenever the ignition switch is turned to ON and a fault occurs in a system. The fault must be corrected to clear the non-resettable warning messages. Inspection and Verification INSPECTION AND VERIFICATION 1. Verify the customer concern. Visual Inspection Chart 2. Visually inspect for obvious signs of mechanical or electrical damage. 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the cause is not visually evident, connect the diagnostic tool to the data link connector and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool 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. 5. If the diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool operating manual. 6. Carry out the diagnostic tool data link test. If the diagnostic tool responds with: - ISO, SCP or CAN circuit fault; all electronic control units no response/not equipped, refer to Information Bus (Module Communications Network). - No response/not equipped for the instrument cluster, refer to Instrument Cluster. - System passed, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs, and carry out self-test diagnostics for the instrument cluster. 7. If the DTCs retrieved are related to the concern, refer to the Instrument Cluster Diagnostic Trouble Code (DTC) Index. See: Diagnostic Trouble Code Descriptions 8. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11236 B1209-U2013 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11237 Driver/Vehicle Information Display: Symptom Related Diagnostic Procedures Symptom Chart (Part 1) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11238 Symptom Chart (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11239 Symptom Chart (Part 3) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11240 Symptom Chart (Part 4) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11241 Symptom Chart (Part 5) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11242 Driver/Vehicle Information Display: Pinpoint Tests Test A: The Message Center Is Not Operating Correctly PINPOINT TEST A: THE MESSAGE CENTER IS NOT OPERATING CORRECTLY A1 Normal Operation The message center functionality is controlled through the message center switches, which are hardwired to the instrument cluster through circuit 1396 (VT/WH) and circuit 1411 (GY/OG). Each message center switch uses a different resistance value allowing the instrument cluster to determine which switch is pressed. Possible Causes - message center switches - instrument cluster Test B: The Compass Is Inoperative PINPOINT TEST B: THE COMPASS IS INOPERATIVE Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11243 B1-B3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11244 B3 Continued Normal Operation The compass sensor module receives voltage from central junction box (CJB) fuse 27 (5A) through circuit 1003 (GY/YE) and is grounded through circuit 875 (BK/LB). The compass sensor module communicates the vehicle direction to the instrument cluster, and the direction is displayed in the message center. The compass sensor module uses circuit 702 (WH/BK) and circuit 703 (WH/OG) to communicate to the instrument cluster. Possible Causes - fuse - circuit 702 (WH/BK) open or short to ground - circuit 703 (WH/OG) open or short to ground - circuit 875 (BK/LB) open - circuit 1003 (GY/YE) open - compass sensor module Test C: The Compass Is Inaccurate PINPOINT TEST C: THE COMPASS IS INACCURATE Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11245 C1-C3 Normal Operation The compass sensor module communicates the vehicle direction to the instrument cluster to display in the message center. Possible Causes - compass sensor module - vehicle magnetization - zone setting - calibration Test D: The Message Center Switch Does Not Operate Correctly PINPOINT TEST D: THE MESSAGE CENTER SWITCH DOES NOT OPERATE CORRECTLY Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11246 D1-D3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11247 D4-D5 Normal Operation The message center switch assembly uses circuits 1396 (VT/WH) and 1411 (GY/OG) to communicate the requested switch function to the message center. Possible Causes - circuit 1396 (VT/WH) open or short to ground - circuit 1411 (GY/OG) open or short to ground - message center switch - instrument cluster Test E: The Power Liftgate Display Is Inoperative PINPOINT TEST E: THE POWER LIFTGATE DISPLAY IS INOPERATIVE E1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11248 E2-E3 Normal Operation The vehicle security module (VSM) sends a voltage reference signal through circuit 700 (WH/VT) to the power liftgate module. When the reference signal loses the ground signal by the opening of the power liftgate, the VSM sends a signal over the communication network to the instrument cluster, illuminating the power liftgate display. Possible Causes - instrument cluster - power liftgate Test F: The Power Running Boards Display Is Inoperative PINPOINT TEST F: THE POWER RUNNING BOARDS DISPLAY IS INOPERATIVE F1-F3 Normal Operation The instrument cluster receives the running board status from the power liftgate module over the communication network. The retractable running boards are controlled by the power liftgate module over the control circuits 1944 (BN/PK) (left side), and 1945 (VT/WH) (right side). The running board motors are grounded through circuit 57 (BK). The retractable running board motors receive a ground signal from the power liftgate module to deploy and an open signal to retract. Possible Causes - instrument cluster - power running boards Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11249 Test G: The Park Assist On/Off Display Is Inoperative PINPOINT TEST G: THE PARK ASSIST ON/OFF DISPLAY IS INOPERATIVE G1-G3 Normal Operation The parking aid system is enabled when the ignition switch is in the RUN position and REVERSE is selected. The system can be disabled through the message center RESET switch located in the instrument cluster. The parking aid menu is displayed until the transmission is taken out of REVERSE. While the menu is displayed, pressing the message center RESET switch changes the parking aid system status to OFF. The parking aid system is disabled if a fault is detected in 1 of the 4 sensors, the parking aid speaker, or the parking aid module. This is indicated by the parking aid disabled warning CHECK BACKUP AID displayed in the message center. The parking aid module communicates with the instrument cluster through the communication network. Possible Causes - instrument cluster - parking aid system Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Page 11250 Driver/Vehicle Information Display: Service and Repair MESSAGE CENTER SWITCH Removal and Installation 1. Remove the instrument cluster finish panel. 2. NOTE: Navigator is shown, Expedition is similar. Press the tabs and remove the message center switch. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Page 11251 Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Filler Cap Warning Indicator > Component Information > Description and Operation Fuel Filler Cap Warning Indicator: Description and Operation CHECK FUEL CAP INDICATOR NOTE: The check fuel cap indicator on the Hanger is a dedicated output signal that is controlled by the PCM. The check fuel cap indicator is a communications network message sent by the PCM. The PCM sends the message to illuminate the lamp when the strategy determines that there is a failure in the vapor management system due to the fuel filler cap not being sealed correctly. This would be detected by the inability to pull vacuum in the fuel tank, after a fueling event. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 11259 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 11260 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 11261 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 11262 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 11263 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 11264 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 11265 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 11266 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 11267 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 11268 Fuel Gauge: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 11269 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 11270 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 11271 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 11272 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 11273 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 11274 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 11275 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump (FP) Module Fuel Gauge Sender: Description and Operation Fuel Pump (FP) Module FUEL PUMP (FP) MODULE Mechanical Returnless Fuel Pump Module (FPM) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump (FP) Module > Page 11280 Electronic Returnless Fuel Pump Module (FPM) The FP module is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump (FP) Module > Page 11281 Fuel Gauge Sender: Description and Operation Fuel Pump Module and Reservoir FUEL PUMP MODULE AND RESERVOIR Fuel Pump Module And Reservoir The fuel pump module is mounted inside the fuel tank in a reservoir. The pump has a discharge check valve that maintains the system pressure after the ignition key has been turned off to minimize starting concerns. The reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low tank fill levels. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > Page 11282 Fuel Gauge Sender: Service and Repair FUEL PUMP MODULE Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > Page 11283 Part 2 Exploded View Special Tool(s) Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > Page 11284 Removal and Installation WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. 1. Remove the fuel tank. 2. Disconnect the fuel and vapor tubes from the fuel pump module. 3. Using the special tool, remove the fuel pump lock ring. 4. CAUTION: Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > Page 11285 - Note the location of the fuel pump alignment tabs. - Carefully remove the fuel pump assembly to avoid damaging the fuel level sensor. Remove the fuel pump module assembly. Remove and discard the O-ring seal. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Depowering and Repowering SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING Depowering Procedure WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the electrical connector on a safety canopy module. Doing so can result in safety canopy deployment. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the RH side of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse 19 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located at the bottom of the hood latch support bracket. The first row side impact sensors (if equipped) are located in the first row doors, behind the door trim panel. The second row side impact sensors (if equipped) are located at or near the base of the C-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install the RCM fuse 19 (10A) to the CJB and close the cover. 4. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11291 Connect the battery ground cable. 5. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a diagnostic tool. Deactivation and Reactivation SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION Special Tool(s) Special Tool(s) Deactivation WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the connectors on the safety canopy module. Doing so can result in safety canopy module deployment. - To reduce the risk of personal injury, do not use any memory saver devices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11292 NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the RH side of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse 19 (10A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located at the bottom of the hood latch support bracket. The first row side impact sensors (if equipped) are located in the first row doors, behind the door trim panel. The second row side impact sensors (if equipped) are located at or near the base of the C-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 7. Remove the 2 steering wheel back cover plugs (1 shown). 8. Remove the 2 driver air bag module bolts (1 shown). Expedition Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11293 9. Remove the driver air bag module. 1 Release the 2 retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector before disconnecting. 2 Release the 2 retaining tabs. Disconnect the driver air bag module electrical connector. Label the driver air bag module squib number on the driver air bag module electrical connector before disconnecting. 3 Disconnect the horn switch electrical connector. 4 Remove the driver air bag module. Navigator 10. Disconnect the driver air bag module. - Release the 2 tabs on each driver air bag module electrical connector and disconnect them. Label each driver air bag module electrical connector before disconnecting. 11. Release the tab and disconnect the driver air bag module accessories electrical connector at the top of the clockspring and remove the driver air bag module. All vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11294 12. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of the steering column. 13. While pushing in on the 2 glove compartment door tabs, position the glove compartment downward. 14. NOTE: Expedition shown, Navigator similar. Through the glove compartment opening, release the tab and disconnect the passenger air bag module electrical connector. 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Vehicles with safety canopies Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11295 16. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or if it does not remain closed, install a new shoulder safety belt guide cover. Remove the second row passenger side safety belt guide. 1 Release the retaining tab at each side and open the safety belt guide cover. 2 Remove the nut. 3 Remove the second row passenger side safety belt guide. 17. Remove the passenger side C-pillar trim panel. 1 Separate the weather-stripping along the passenger side C-pillar trim panel. 2 Remove the bolt cover and bolt. 3 Pull out to release the retainers and remove the passenger side C-pillar trim panel. 18. Disconnect the passenger side safety canopy electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11296 19. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy electrical connector. 20. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or if it does not remain closed, install a new shoulder safety belt guide cover. Remove the second row driver side safety belt guide. 1 Release the retaining tab at each side and open the safety belt guide cover. 2 Remove the nut. 3 Remove the second row driver side safety belt guide. 21. Remove the driver side C-pillar trim panel. 1 Separate the weather-stripping along the driver side C-pillar trim panel. 2 Remove the bolt cover and bolt. 3 Pull out to release the retainers and remove the driver side C-pillar trim panel. 22. Disconnect the driver side safety canopy electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11297 23. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy electrical connector. All vehicles 24. Install the RCM fuse 19 (10A) to the CJB. 25. Connect the battery ground cable. Reactivation All vehicles 1. Remove the RCM fuse 19 (10A) from the CJB. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles with safety canopies 3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy electrical connector. 4. Connect the driver side safety canopy electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11298 5. WARNING: Anytime the safety canopy module has deployed, the headliner, and all A, B, and C pillar upper trim panels and attaching hardware must be replaced along with any other damaged components and hardware. Failure to do so may result in personal injury in the event of a safety canopy module deployment. Install the driver side C-pillar trim panel. 1 Position the driver side C-pillar trim panel and push in, engaging the retainers. 2 Install the bolt and bolt cover. Tighten to 11 Nm (8 lb-ft). 3 Install the weather-stripping along the driver side C-pillar trim panel. 6. NOTE: - Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or if it does not remain closed, install a new shoulder safety belt guide cover. - Make sure the safety belt is not twisted prior to installation. Install the second row driver side safety belt guide. 1 Position the second row driver side safety belt guide. 2 Install the nut. Tighten to 40 Nm (30 lb-ft). 3 Close the safety belt guide cover. Verify the safety belt retractor operates without excessive effort or binding. 7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11299 8. Connect the passenger side safety canopy electrical connector. 9. WARNING: Anytime the safety canopy module has deployed, the headliner, and all A, B, and C pillar upper trim panels and attaching hardware must be replaced along with any other damaged components and hardware. Failure to do so may result in personal injury in the event of a safety canopy module deployment. Install the passenger C-pillar trim panel. 1 Position the passenger side C-pillar trim panel and push in, engaging the retainers. 2 Install the bolt and bolt cover. Tighten to 11 Nm (8 lb-ft). 3 Install the weather-stripping along the passenger side C-pillar trim panel. 10. NOTE: - Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or if it does not remain closed, install a new shoulder safety belt guide cover. - Make sure the safety belt is not twisted prior to installation. Install the second row passenger side safety belt guide. 1 Position the second row passenger side safety belt guide. 2 Install the nut. Tighten to 40 Nm (30 lb-ft). 3 Close the safety belt guide cover. Verify the safety belt retractor operates without excessive effort or binding. All vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11300 11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. 12. NOTE: Expedition shown, Navigator similar. Connect the passenger air bag module electrical connector. 13. Close the glove compartment. 14. Remove the restraint system diagnostic tools from the clockspring electrical connector at the top of the steering column. Navigator 15. Connect the driver air bag module accessories electrical connector to the connector end at the top of the clockspring. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11301 16. CAUTION: The clockspring electrical connectors are unique and cannot be reversed when connected to the driver air bag module. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Connect the driver air bag module electrical connectors as noted during removal. Position the driver air bag module to the steering wheel. Expedition 17. Position the driver air bag module to the steering wheel. 1 Connect the horn switch electrical connector. 2 CAUTION: The clockspring electrical connectors are unique and cannot be reversed when connected to the driver air bag module. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Connect the driver air bag module electrical connectors as noted during removal. 3 Position the driver air bag module to the steering wheel. All vehicles 18. Install the 2 driver air bag module bolts (1 shown). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11302 19. Install the 2 steering wheel back cover plugs (1 shown). 20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse 19 (10A) to the CJB and close the cover. 23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a diagnostic tool. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11303 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure PROVE OUT PROCEDURE Turn the ignition switch from the OFF to the ON position and visually monitor the air bag indicator with all SRS components connected or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an SRS fault is present, the air bag indicator will: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Service and Repair > Instrument Cluster Bulb Instrument Panel Bulb: Service and Repair Instrument Cluster Bulb INSTRUMENT CLUSTER BULB Removal and Installation 1. Remove the instrument cluster. 2. Remove the instrument cluster illumination bulbs. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Service and Repair > Instrument Cluster Bulb > Page 11308 Instrument Panel Bulb: Service and Repair Warning Indicator Bulb WARNING INDICATOR BULB Removal and Installation All vehicles 1. Remove the instrument cluster. Expedition 2. NOTE: To remove a warning indicator bulb, rotate the bulb one quarter turn counterclockwise and lift it out from the instrument cluster. Remove the warning indicator bulb(s) in question. Navigator 3. Release the clips and remove the rear cover. 4. NOTE: To remove a warning indicator bulb, rotate the bulb one quarter turn counterclockwise and lift it out from the instrument cluster. Remove the warning indicator bulb(s) in question. All vehicles 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Description and Operation Low Tire Pressure Indicator: Description and Operation UNDERSTANDING YOUR TIRE PRESSURE MONITORING SYSTEM (TPMS) The Tire Pressure Monitoring System measures pressure in your four road tires and sends the tire pressure readings to your vehicle every minute while you are driving and once every 6 hours when your vehicle is parked. The Low Tire Warning Lamp will turn ON if the tire pressure is 25% below the pressure listed on the Safety Compliance Certification Label (approximately 6 to 9 psi below the manufacturers recommend tire pressure). If the tire pressure increases 2 psi above the Light ON threshold, then the TPMS light will turn OFF. Once the light is illuminated, your tires are under inflated and need to be inflated to the manufacturers recommended tire pressure. Even if the light turns ON and a short time later turns OFF, your tire pressure still needs to be checked. In short, once the light has turned ON, at least one tire may be under inflated. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Description and Operation > Page 11312 Low Tire Pressure Indicator: Testing and Inspection TPM's Indicator and Vehicle Message Center Messages The TPM's indicator and vehicle message center (if equipped) sometimes displays faults that cannot be resolved by the customer. Treat these messages as TPM's faults that must be serviced. GO to Symptom Chart for the TPM's indicator operation and message center messages. See: Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures CAUTION: Place the air chuck straight on the valve stem to inflate the tire. Do not cock the air chuck during the inflation cycle. Doing so can damage the valve stem and cause air leaks. CAUTION: Ford recommends using a round head air chuck on tire pressure sensors; it is not recommended to use air chucks with long shanks. Doing so can cause tire pressure sensor valve stem damage and loss of tire pressure. TPM's Indicator Illuminates Continuously The TPM's indicator remains on continuously for the following condition: 1. NOTE: If the spare tire is in use, the damaged road tire must be repaired and installed on the vehicle to restore complete TPM's functionality before carrying out any diagnosis. Low Tire Pressure - The TPM's indicator is illuminated solid and the message center displays LOW TIRE PRESSURE (if equipped). This is displayed when any of the tire pressures are low. Tire pressure must be adjusted to the recommended cold placard pressure. Adjust the air pressure in tires. Refer to Information BUS for diagnosis of the CAN bus. The TPM's indicator flashes for 20 seconds after prove-out and for the following 3 reasons: 1 No communication with the TPM's Module (integral to VSM) - The TPM's indicator is illuminated when the instrument cluster (IC) has received no signals from the VSM for more than 5 seconds. If equipped, the message center displays TIRE PRESSURE MONITOR FAULT. GO to Symptom Chart. See: Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures 2 Tire Pressure Sensor Fault - If equipped, the message center will display TIRE PRESSURE SENSOR FAULT when a tire pressure sensor is malfunctioning. GO to Symptom Chart. See: Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures 3 Tire Pressure Monitor Fault - If equipped, the message center will display TIRE PRESSURE MONITOR FAULT when the tire pressure monitoring system is malfunctioning. GO to Symptom Chart. See: Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair Maintenance Required Lamp/Indicator: Service and Repair This vehicle is not equipped with a maintenance required lamp/indicator. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) MIL (applications With A Dedicated Hard Wire MIL Circuit) CHECK ENGINE, SERVICE ENGINE SOON, Or ISO Standard Engine Symbol The MIL notifies the driver that the powertrain control module (PCM) has detected an on board diagnostic (OBD) emission-related component or system concern. When this occurs, an OBD diagnostic trouble code (DTC) sets. - The MIL is located in the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE SOON or the international standards organization (ISO) standard engine symbol. - The MIL is illuminated during the instrument cluster prove out for approximately 4 seconds. - For applications with a dedicated hard wire MIL circuit, the PCM illuminates the MIL until a profile ignition pickup (PIP) signal is detected. The Ranger uses a hard wire circuit. - The MIL remains illuminated after instrument cluster prove out if: an emission-related concern and DTC exists. - no PIP signal is detected (applications with a dedicated hard wire MIL circuit). The PIP signal is generated in the PCM using the crankshaft position (CKP) sensor. For these applications, the MIL can be helpful in diagnosing a no start. - the PCM does not send a control message to the instrument cluster (applications with the MIL controlled through the communication link). - the PCM is operating in the Hardware Limited Operation Strategy (HLOS). - the MIL circuit is shorted to ground (applications with a dedicated hard wire MIL circuit). - The MIL remains off during the instrument cluster prove out if: an indicator or instrument cluster concern is present. - the MIL circuit is open (applications with a dedicated hard wire MIL circuit). - To turn off the MIL after a repair, a reset command from the diagnostic tool must be sent, or 3 consecutive drive cycles must be completed without a concern. - For all MIL concerns, go to Symptom Charts. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures - If the MIL flashes at a steady rate, a severe misfire condition may exist. - If the MIL flashes erratically, the PCM can reset while cranking if the battery voltage is low. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 This vehicle is not equipped with an oil change reminder lamp. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations View 151-4 (Engine, Front) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 11325 C103 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Warning Indicator: > 06-20-5 > Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743 Parking Assist Warning Indicator: Customer Interest Parking Assist System - Speaker Inop./DTC C1742/C1743 TSB 06-20-5 10/16/06 PARKING AID SPEAKER INOPERATIVE - DTCS C1742 AND C1743 FORD: 2005-2007 Five Hundred, Freestyle 2004-2006 Escape, Expedition, Explorer, F-150 2004-2007 F-250, F-350 MERCURY: 2005-2007 Montego 2004-2006 Mountaineer 2005-2006 Mariner ISSUE Some 2004-2007 vehicles equipped with the parking aid reverse sensing system (RSS) may experience low or no audible sound due to speaker issues related to the RSS. The speaker is attached to the module which may exhibit diagnostic trouble codes (DTCs) C1742 (Rear Sounder Circuit Fault) and/or C1743 (Rear Sounder Short). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Verify that DTCs C1742 and/or C1743 are present. Also, low audible or intermittent audible warning condition may exist as well. 2. If DTCs C1742 and/or C1743 are present, replace parking aid speaker on module with speaker in Speaker Kit. Follow instructions in Speaker Kit. 3. Clear DTCs and repeat check for DTCs C1742 and/or C1743. 4. If DTCs C1742 and/or C1743 go away and speaker sounds, the repair is complete. 5. If DTCs remain, follow normal diagnostics in the appropriate Workshop Manual, Section 413-13 Pinpoint Test F. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 062005A 2004-2006 Expedition: 1.2 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2007 Super Duty 0.6 Hr. 250/350: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Warning Indicator: > 06-20-5 > Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743 > Page 11334 062005A 2004-2005 1.1 Hrs. Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2006 Explorer/Mountaineer: 1.3 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 F-150: Replace 0.5 Hr. Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 Escape, 0.8 Hr. 2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Five 1.3 Hrs. Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Freestyle: 0.7 Hr. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR 31012AL, 31012AT) DEALER CODING CONDITION BASIC PART NO. CODE 15K864 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Warning Indicator: > 06-20-5 > Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743 Parking Assist Warning Indicator: All Technical Service Bulletins Parking Assist System - Speaker Inop./DTC C1742/C1743 TSB 06-20-5 10/16/06 PARKING AID SPEAKER INOPERATIVE - DTCS C1742 AND C1743 FORD: 2005-2007 Five Hundred, Freestyle 2004-2006 Escape, Expedition, Explorer, F-150 2004-2007 F-250, F-350 MERCURY: 2005-2007 Montego 2004-2006 Mountaineer 2005-2006 Mariner ISSUE Some 2004-2007 vehicles equipped with the parking aid reverse sensing system (RSS) may experience low or no audible sound due to speaker issues related to the RSS. The speaker is attached to the module which may exhibit diagnostic trouble codes (DTCs) C1742 (Rear Sounder Circuit Fault) and/or C1743 (Rear Sounder Short). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Verify that DTCs C1742 and/or C1743 are present. Also, low audible or intermittent audible warning condition may exist as well. 2. If DTCs C1742 and/or C1743 are present, replace parking aid speaker on module with speaker in Speaker Kit. Follow instructions in Speaker Kit. 3. Clear DTCs and repeat check for DTCs C1742 and/or C1743. 4. If DTCs C1742 and/or C1743 go away and speaker sounds, the repair is complete. 5. If DTCs remain, follow normal diagnostics in the appropriate Workshop Manual, Section 413-13 Pinpoint Test F. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 062005A 2004-2006 Expedition: 1.2 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2007 Super Duty 0.6 Hr. 250/350: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Warning Indicator: > 06-20-5 > Oct > 06 > Parking Assist System - Speaker Inop./DTC C1742/C1743 > Page 11340 062005A 2004-2005 1.1 Hrs. Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2006 Explorer/Mountaineer: 1.3 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 F-150: Replace 0.5 Hr. Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 Escape, 0.8 Hr. 2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Five 1.3 Hrs. Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Freestyle: 0.7 Hr. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR 31012AL, 31012AT) DEALER CODING CONDITION BASIC PART NO. CODE 15K864 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator > Component Information > Technical Service Bulletins > Page 11341 C4015 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations View 151-15 (LH A-Pillar) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 11345 C2015 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Description and Operation Seat Belt Reminder Buzzer: Description and Operation Warning System - Driver Safety Belt The driver safety belt incorporates a safety belt warning indicator switch, warning indicator and chime. The warning indicator and chime are reminders to fasten the safety belt. If the driver safety belt is not buckled before the ignition key is turned to ON, the safety belt warning light illuminates for 1 to 2 minutes and the warning chime sounds for 4 to 8 seconds. - If the driver side safety belt is buckled while the indicator light is illuminated and the warning chime is sounding, the safety belt warning light and warning chime turn OFF. - If the safety belt is buckled before the key is turned to the ON position, the warning indicator will come on for 4 to 8 seconds with no chime. Belt Minder (if equipped) The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning lamp in the instrument cluster. To activate or deactivate the Belt Minder feature, refer to Seat Belt Systems or the owner's literature. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation Warning System - Driver Safety Belt The driver safety belt incorporates a safety belt warning indicator switch, warning indicator and chime. The warning indicator and chime are reminders to fasten the safety belt. If the driver safety belt is not buckled before the ignition key is turned to ON, the safety belt warning light illuminates for 1 to 2 minutes and the warning chime sounds for 4 to 8 seconds. - If the driver side safety belt is buckled while the indicator light is illuminated and the warning chime is sounding, the safety belt warning light and warning chime turn OFF. - If the safety belt is buckled before the key is turned to the ON position, the warning indicator will come on for 4 to 8 seconds with no chime. Belt Minder (if equipped) The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning lamp in the instrument cluster. To activate or deactivate the Belt Minder feature, refer to Seat Belt Systems or the owner's literature. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair Dimmer Switch: Service and Repair INSTRUMENT PANEL DIMMER SWITCH Removal and Installation 1. Remove the instrument panel finish panel. - Disconnect the electrical connectors. 2. Press the tabs and remove the instrument panel dimmer switch. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear View 151-30 (Left Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 11360 View 151-28 (Driver Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 11361 View 151-29 (Passenger Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 11362 View 151-31 (Right Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 11363 View 151-32 (Liftgate) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch C479 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 11366 C526 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 11367 C602 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 11368 C715 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 11369 C820 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 11370 Door Switch: Service and Repair DOOR AJAR SWITCH Removal and Installation 1. Remove the door lock actuator. 2. Release the locking tab and remove the door ajar switch. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump (FP) Module Fuel Gauge Sender: Description and Operation Fuel Pump (FP) Module FUEL PUMP (FP) MODULE Mechanical Returnless Fuel Pump Module (FPM) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump (FP) Module > Page 11375 Electronic Returnless Fuel Pump Module (FPM) The FP module is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump (FP) Module > Page 11376 Fuel Gauge Sender: Description and Operation Fuel Pump Module and Reservoir FUEL PUMP MODULE AND RESERVOIR Fuel Pump Module And Reservoir The fuel pump module is mounted inside the fuel tank in a reservoir. The pump has a discharge check valve that maintains the system pressure after the ignition key has been turned off to minimize starting concerns. The reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low tank fill levels. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 11377 Fuel Gauge Sender: Service and Repair FUEL PUMP MODULE Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 11378 Part 2 Exploded View Special Tool(s) Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 11379 Removal and Installation WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. 1. Remove the fuel tank. 2. Disconnect the fuel and vapor tubes from the fuel pump module. 3. Using the special tool, remove the fuel pump lock ring. 4. CAUTION: Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 11380 - Note the location of the fuel pump alignment tabs. - Carefully remove the fuel pump assembly to avoid damaging the fuel level sensor. Remove the fuel pump module assembly. Remove and discard the O-ring seal. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations View 151-15 (LH A-Pillar) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 11384 C2015 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Description and Operation Low Tire Pressure Indicator: Description and Operation UNDERSTANDING YOUR TIRE PRESSURE MONITORING SYSTEM (TPMS) The Tire Pressure Monitoring System measures pressure in your four road tires and sends the tire pressure readings to your vehicle every minute while you are driving and once every 6 hours when your vehicle is parked. The Low Tire Warning Lamp will turn ON if the tire pressure is 25% below the pressure listed on the Safety Compliance Certification Label (approximately 6 to 9 psi below the manufacturers recommend tire pressure). If the tire pressure increases 2 psi above the Light ON threshold, then the TPMS light will turn OFF. Once the light is illuminated, your tires are under inflated and need to be inflated to the manufacturers recommended tire pressure. Even if the light turns ON and a short time later turns OFF, your tire pressure still needs to be checked. In short, once the light has turned ON, at least one tire may be under inflated. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Description and Operation > Page 11389 Low Tire Pressure Indicator: Testing and Inspection TPM's Indicator and Vehicle Message Center Messages The TPM's indicator and vehicle message center (if equipped) sometimes displays faults that cannot be resolved by the customer. Treat these messages as TPM's faults that must be serviced. GO to Symptom Chart for the TPM's indicator operation and message center messages. See: Testing and Inspection/Symptom Related Diagnostic Procedures CAUTION: Place the air chuck straight on the valve stem to inflate the tire. Do not cock the air chuck during the inflation cycle. Doing so can damage the valve stem and cause air leaks. CAUTION: Ford recommends using a round head air chuck on tire pressure sensors; it is not recommended to use air chucks with long shanks. Doing so can cause tire pressure sensor valve stem damage and loss of tire pressure. TPM's Indicator Illuminates Continuously The TPM's indicator remains on continuously for the following condition: 1. NOTE: If the spare tire is in use, the damaged road tire must be repaired and installed on the vehicle to restore complete TPM's functionality before carrying out any diagnosis. Low Tire Pressure - The TPM's indicator is illuminated solid and the message center displays LOW TIRE PRESSURE (if equipped). This is displayed when any of the tire pressures are low. Tire pressure must be adjusted to the recommended cold placard pressure. Adjust the air pressure in tires. Refer to Information BUS for diagnosis of the CAN bus. The TPM's indicator flashes for 20 seconds after prove-out and for the following 3 reasons: 1 No communication with the TPM's Module (integral to VSM) - The TPM's indicator is illuminated when the instrument cluster (IC) has received no signals from the VSM for more than 5 seconds. If equipped, the message center displays TIRE PRESSURE MONITOR FAULT. GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures 2 Tire Pressure Sensor Fault - If equipped, the message center will display TIRE PRESSURE SENSOR FAULT when a tire pressure sensor is malfunctioning. GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures 3 Tire Pressure Monitor Fault - If equipped, the message center will display TIRE PRESSURE MONITOR FAULT when the tire pressure monitoring system is malfunctioning. GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Module > Component Information > Service and Repair Tire Pressure Module: Service and Repair Tire Pressure Monitoring System Module Removal and Installation CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: The tire pressure monitoring system (TPM's) is integral to the vehicle security module (VSM) and is not serviced separately. NOTE: A new VSM module is delivered in manufacturing mode with pre-set diagnostic trouble codes (DTC's). These DTC's require that a particular set of operations to be carried out in order to clear them and enable the module for normal operations. The pre-set DTC's are as follows: ^ B2477 - Module Configuration Failure/Mismatch ^ B2868 - Left Front Tire Pressure Sensor Fault ^ B2869 - Right Front Tire Pressure Sensor Fault ^ B2870 - Left Rear Tire Pressure Sensor Fault ^ B2871 - Right Rear Tire Pressure Sensor Fault ^ C2780 - ECU in Manufacturing Mode NOTE: A re-configured VSM may also set the above codes and will need to go through the same set of procedures as a new module to enable normal operation. 1. NOTE: The steps included in the VSM removal and installation process are critical to restoring vehicle security and tire pressure monitoring system operations and will permit a new or reconfigured module to operate as intended. Each step is designed to carry out a particular operation and clear the manufacturing mode DTC's. Once these DTC's are cleared, the new or reconfigured module will enter into normal operating mode. Remove the VSM. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection Tire Pressure Sensor: Testing and Inspection Sensor Training (Reset Procedure) NOTE: The tire pressure monitoring system is not affected by wheel and tire rotation. NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area without radio frequency (RF) noise. RF noise is generated by electrical motor and appliance operation, cellular telephones and remote transmitters, power inverters and portable entertainment equipment. 1. Turn the ignition switch to the OFF position. 2. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. Do not wait more than 1 minute between each key cycle. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. Do not wait more than 1 minute between each key cycle. 6. The horn will sound once and the TPMS indicator will flash if train mode has been entered successfully. If equipped, the message center displays "TRAIN LF TIRE", place the special tool on the valve stem of the LF tire pressure sensor. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the TPMS module. 7. Within 2 minutes after the horn sounds, place the special tool on the valve stem of the RF tire pressure sensor. NOTE: If the VSM (TPMS module integral to VSM) does not recognize any 1 of the 4 tire pressure sensors during the tire training procedure, the horn will sound twice and the message center (if equipped) will display "TIRE NOT TRAINED REPEAT" and the procedure must be repeated. 8. Repeat Step 7 for the RR and LR tires. When the tire training procedure is complete, the horn will sound once and the message center (if equipped) will display "TIRE TRAINING MODE COMPLETE". Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 11396 Tire Pressure Sensor: Service and Repair Tire Pressure Sensor Special Tools CAUTION: Use only special tool 204-354 anytime tire pressures are measured to be sure that accurate values are obtained. CAUTION: Place the air chuck straight on the valve stem to inflate the tire. Do not cock the air chuck during the inflation cycle. Doing so can damage the valve stem and cause air leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 11397 CAUTION: Ford recommends using a round head air chuck on tire pressure sensors; it is not recommended to use air chucks with long shanks. Doing so can cause tire pressure sensor valve stem damage and loss of tire pressure. Removal NOTE: The vehicle is equipped with a light blue-colored tire pressure sensor. When installing new components, use only this tire pressure sensor. The tire pressure monitoring system (TPM's) will not operate correctly if black-colored tire pressure sensors are installed. 1. Remove the wheel and tire assembly. 2. CAUTION: Do not remove the valve stem core to relieve the tire pressure. CAUTION: If the valve stem core has been removed from the valve stem, reinstall the original valve stem core. If the original valve stem core is damaged, a nickel-plated core must be installed. Failure to use a nickel-plated core will result in corrosion and the possible loss of tire pressure. NOTE: Release the tire pressure by removing the sensor valve stem nut. With the valve stem at the 6 o'clock position, remove the sensor valve stem nut and push the sensor by hand into the tire (with the cap on). 3. Using a suitable tire machine, separate both beads of the tire from the wheel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 11398 4. CAUTION: Care should be taken not to damage the tire pressure sensor while separating the outside bead of tire from the wheel. Place the wheel and tire on the turntable of the tire machine, index-mark the valve stem and wheel weight positions, lubricate the bead of the tire and dismount the outside bead of the tire from the wheel. 5. Remove the tire pressure sensor from the tire. 6. Remove and discard the grommet from the tire pressure sensor. Installation NOTE: The vehicle is equipped with a light blue-colored tire pressure sensor. When installing new components, use only this tire pressure sensor. The TPM's will not operate correctly if black-colored tire pressure sensors are installed. 1. NOTE: Install a new sensor grommet or an air leak can occur. Install a new grommet on the tire pressure sensor. 2. NOTE: Do not allow the tire to rotate relative to the rim while mounting the tire. Lubricate and mount the outside and inside bead of the tire to the rim. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 11399 3. CAUTION: Overtightening the tire pressure sensor valve stem nut can damage the tire pressure sensor, undertightening can cause air leaks. NOTE: Sensor position is critical for correct sensor operation. The "flat" side of the sensor must be facing the wheel and the "slanted" side of the sensor must be facing away from the wheel. When properly installed, there will be a very small gap between the sensor and the wheel. NOTE: Tightening the nut to 5 Nm (44 inch lbs.) equals approximately 2 clockwise turns after the nut has been tightened by hand. Push the side wall of the tire and install the tire pressure sensor. Tighten the nut to 5 Nm (44 inch lbs.). 4. CAUTION: Use only special tool 204-354 anytime tire pressures are measured to be sure that accurate values are obtained. CAUTION: Place the air chuck straight on the valve stem to inflate the tire. Do not cock the air chuck during the inflation cycle. Doing so can damage the valve stem and cause air leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 11400 CAUTION: Ford recommends using a round head air chuck on tire pressure sensors; it is not recommended to use air chucks with long shanks. Doing so can cause tire pressure sensor valve stem damage and loss of tire pressure. CAUTION: Use only OEM valve caps (aluminum or plastic valve caps) with the tire pressure sensors. Do not use brass-threaded valve caps with the tire pressure sensors. Inflate the tire to the pressure specified on the safety certification sticker located on the driver or door pillar. 5. Install the wheel and tire assembly. 6. Train the tire pressure sensors. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation TRANSMISSION CONTROL INDICATOR LAMP (TCIL) The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Service and Repair Ambient Light Sensor: Service and Repair LIGHT SENSOR Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Service and Repair > Page 11408 Removal and Installation Expedition 1. Remove the light sensor and bezel as an assembly from the defroster grille. - Disconnect the electrical connector. 2. Remove the 2 screws and the light sensor. Navigator 3. Remove the defroster grille. 4. Remove the 2 screws and the light sensor. - Disconnect the electrical connector. All vehicles 5. To install, reverse the removal procedure Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Locations > Page 11413 C1474 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Locations > Page 11414 Backup Lamp Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Locations > Page 11415 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 11419 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 11420 C167 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions Brake Lamp: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11425 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11426 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11427 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11428 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11429 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11430 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11431 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11432 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11433 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11434 Brake Lamp: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11435 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11436 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11437 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11438 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11439 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11440 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11441 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11442 Brake Lamp: Connector Views C4032 C4035 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11443 Brake Lamp: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 90-1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11444 90-2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11445 90-3 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. See: Diagrams/Components/Component Location Views Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Brake Lamp: Initial Inspection and Diagnostic Overview INSPECTION AND VERIFICATION 1. Verify the customer concern. Visual Inspection Chart 2. Visually inspect for obvious signs of mechanical or electrical damage. 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the concern is not visually evident, verify the symptom and GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11448 Symptom Chart Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11449 Brake Lamp: Pinpoint Tests Test H: The Stoplamps Are Inoperative PINPOINT TEST H: THE STOPLAMPS ARE INOPERATIVE H1-H2 Normal Operation The stoplamp switch is supplied voltage from the central junction box (CJB) fuse 2 (20A) through circuit 10 (LG/RD). When the brake pedal is applied, the stoplamp switch routes voltage to the stoplamps through circuit 511 (LG). Possible Causes - Fuse - Circuit 10 (LG/RD) open - Circuit 511 (LG) open - Stoplamp switch Test I: One Or More Stoplamps Are Inoperative PINPOINT TEST I: ONE OR MORE STOPLAMPS ARE INOPERATIVE Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11450 I1-I4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11451 I4-I5 Normal Operation When the brake pedal is applied, the stoplamp switch routes voltage to the high mounted stoplamp and the multifunction switch through circuit 511 (LG). The multifunction switch then routes the voltage to the central junction box (CJB) through circuit 9 (LG/OG) and circuit 5 (OG/LB). The CJB then routes the voltage to the LH stoplamp and RH stoplamp through circuit 9 (LG/OG) and circuit 5 (OG/LB) respectively. Possible Causes - Circuit 5 (OG/LB) open - Circuit 9 (LG/OG) open - Circuit 511 (LG) open - Multifunction switch - CJB Test J: The Stoplamps Are On Continuously PINPOINT TEST J: THE STOPLAMPS ARE ON CONTINUOUSLY Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11452 J1-J6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11453 J7 Normal Operation The stoplamp switch is supplied voltage from the central junction box (CJB) fuse 2 (20A) through circuit 10 (LG/RD). When the brake pedal is applied, the stoplamp switch routes voltage to the high mounted stoplamp and the multifunction switch through circuit 511 (LG). The multifunction switch then routes the voltage to the CJB through circuit 9 (LG/OG) and circuit 5 (OG/LB). The CJB then routes the voltage to the LH stoplamp and RH stoplamp through circuit 9 (LG/OG) and circuit 5 (OG/LB) respectively. Possible Causes - Circuit 5 (OG/LB) short to voltage - Circuit 9 (LG/OG) short to voltage - Circuit 52 (YE) short to voltage - Circuit 64 (DG) short to voltage - Circuit 511 (LG) short to voltage - Stoplamp switch - Multifunction switch - Trailer tow electric brake controller - CJB Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Page 11454 Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations View 151-10 (behind Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 11458 C278 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 11459 Brake Light Switch: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - BPP switch is hardwired to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - BPP switch is hardwired to the Anti-Lock Brake System (ABS) Module, Lighting Control Module (LCM), or Rear Electronic Module (REM), the BPP signal is then broadcast over the network to be received by the PCM. - BPP switch is hardwired to the anti-lock brake system (ABS) traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 11460 Brake Light Switch: Service and Repair STOPLAMP SWITCH Removal and Installation 1. Disconnect the stoplamp switch electrical connector. 2. Remove the self-locking pin. 3. Remove the stoplamp switch from the brake booster push rod and the brake pedal assembly. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams C926 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams C475 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams Ash Tray Lamp: Diagrams C2014 C2246 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information > Locations Courtesy Lamp Relay: Locations View 151-12 (Dash Panel) The interior lamp relay is located in the instrument cluster and is Not Serviceable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams C254 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Interior Light Switch > Component Information > Service and Repair Interior Light Switch: Service and Repair INTERIOR LAMP SWITCH Removal and Installation 1. Remove the door trim panel. 2. Remove the interior lamp switch. 1 Disconnect the electrical connector. 2 Rotate the interior lamp switch one-quarter turn counterclockwise and remove. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Locations > Daytime Running Lamps (DRL) Headlamp Relay Daytime Running Lamp Relay: Locations Daytime Running Lamps (DRL) Headlamp Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Locations > Daytime Running Lamps (DRL) Headlamp Relay > Page 11485 View 151-1 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Locations > Daytime Running Lamps (DRL) Headlamp Relay > Page 11486 Daytime Running Lamp Relay: Locations Daytime Running Lamps (DRL) Ignition Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Locations > Daytime Running Lamps (DRL) Headlamp Relay > Page 11487 View 151-1 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Daytime Running Lamps (DRL) Headlamp Relay C1359 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Daytime Running Lamps (DRL) Headlamp Relay > Page 11490 C1171 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Daytime Running Lamps (DRL) Headlamp Relay Daytime Running Lamp Relay: Testing and Inspection Daytime Running Lamps (DRL) Headlamp Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Daytime Running Lamps (DRL) Headlamp Relay > Page 11493 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Daytime Running Lamps (DRL) Headlamp Relay > Page 11494 Daytime Running Lamp Relay: Testing and Inspection Daytime Running Lamps (DRL) Ignition Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Daytime Running Lamps (DRL) Headlamp Relay > Page 11495 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Service and Repair Dimmer Switch: Service and Repair INSTRUMENT PANEL DIMMER SWITCH Removal and Installation 1. Remove the instrument panel finish panel. - Disconnect the electrical connectors. 2. Press the tabs and remove the instrument panel dimmer switch. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations Battery Discharge Protection Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 11502 View 151-1 (Engine Compartment) The battery savar relay is part of the central junction box (CJB) and is Not Serviceable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear View 151-30 (Left Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 11507 View 151-28 (Driver Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 11508 View 151-29 (Passenger Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 11509 View 151-31 (Right Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 11510 View 151-32 (Liftgate) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch C479 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 11513 C526 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 11514 C602 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 11515 C715 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 11516 C820 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Page 11517 Door Switch: Service and Repair DOOR AJAR SWITCH Removal and Installation 1. Remove the door lock actuator. 2. Release the locking tab and remove the door ajar switch. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair Fog/Driving Lamp Bulb: Service and Repair FOG LAMP BULB Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair > Page 11522 Removal and Installation 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. Failure to follow these instructions may result in personal injury. NOTE: The fog lamp bulb should not be removed from the fog lamp until just before a new bulb is installed. Removing the bulb for an extended period of time may affect headlamp bulb performance. Contaminants may enter the headlamp where they can settle on the lens and reflector. Never turn on the fog lamp with the bulb removed from the fog lamp. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: Make sure the headlamp switch and the ignition switch are in the OFF position. Disconnect the electrical connector and remove the fog lamp bulb. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 11526 C2241 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 11527 Fog/Driving Lamp Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 11528 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information > Locations > Page 11533 C2047 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information > Locations > Page 11534 Hazard Flasher Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information > Locations > Page 11535 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection Hazard Warning Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Page 11539 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Page 11540 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair Headlamp Bulb: Service and Repair HEADLAMP BULB Headlamp Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > Page 11545 Standard Headlamp Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > Page 11546 High Intensity Discharge (HID) Headlamp Removal and Installation All vehicles CAUTION: 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. Failure to follow these instructions may result in damage to the headlamp bulb. NOTE: - The headlamp bulb should not be removed from the headlamp until just before a new bulb is installed. Removing the bulb for an extended period of time may affect headlamp bulb performance. Contaminants may enter the headlamp where they can settle on the lens and reflector. Never turn on the headlamp with the bulb removed from the headlamp. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > Page 11547 - Make sure that the headlamp switch and the ignition switch are in the OFF position. 1. Remove the headlamp assembly. Expedition or Navigator halogen bulb 2. Remove the headlamp bulb access cover. 3. CAUTION: Bulbs 9006 and 9005 look similar, but are not interchangeable. Failure to follow these instructions may result in damage to the headlamp bulb. Disconnect the electrical connector and remove the headlamp bulb. Navigator HID headlamp 4. Remove the low beam bulb access cover. 5. Release the spring tabs and remove the HID low beam bulb. - Disconnect the electrical connector. All vehicles 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations View 151-14 (Steering Column) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations > Page 11551 Headlamp Dimmer Switch: Diagrams C202a C202b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations > Page 11552 C202c Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations > Page 11553 Headlamp Dimmer Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations > Page 11554 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations View 151-12 (Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 11558 Headlamp Switch: Diagrams C205a C205b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 11559 C205c Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Testing and Inspection > Main Light Switch, Exterior Lamps Headlamp Switch: Testing and Inspection Main Light Switch, Exterior Lamps Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Testing and Inspection > Main Light Switch, Exterior Lamps > Page 11562 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Testing and Inspection > Main Light Switch, Exterior Lamps > Page 11563 Headlamp Switch: Testing and Inspection Main Light Switch, Interior Lamps Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Testing and Inspection > Main Light Switch, Exterior Lamps > Page 11564 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Testing and Inspection > Page 11565 Headlamp Switch: Service and Repair HEADLAMP SWITCH Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Testing and Inspection > Page 11566 Removal and Installation Expedition 1. CAUTION: Cover the end of the tool with tape to prevent damage to the trim panel. NOTE: Use a thin-bladed tool to remove the headlamp switch bezel assembly. Remove the headlamp switch and bezel assembly. Disconnect the electrical connectors. Navigator 2. Remove the instrument panel finish panel. 3. NOTE: Release the tabs to remove the headlamp switch. Remove the 2 screws and the headlamp switch. All vehicles 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Headlamp > High Beam Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Headlamp > High Beam Relay > Component Information > Locations > Page 11570 C2242 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Headlamp > High Beam Relay > Component Information > Locations > Page 11571 High Beam Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Headlamp > High Beam Relay > Component Information > Locations > Page 11572 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 11577 View 151-1 (Engine Compartment) The horn relay is part of the central junction box (CJB) and is Not Serviceable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Locations Interior Lighting Relay: Locations View 151-12 (Dash Panel) The interior lamp relay is located in the instrument cluster and is Not Serviceable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions License Plate Lamp: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11585 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11586 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11587 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11588 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11589 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11590 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11591 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11592 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11593 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11594 License Plate Lamp: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11595 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11596 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11597 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11598 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11599 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11600 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11601 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11602 License Plate Lamp: Connector Views C452 C462 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11603 License Plate Lamp: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 92-1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11604 92-2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11605 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. See: Diagrams/Components/Component Location Views Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Map Reading Lamp, Left Front C908 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Map Reading Lamp, Left Front > Page 11610 C903 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Side Lamp, Left Front C151 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Side Lamp, Left Front > Page 11615 C161 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Electronic Park Brake Release Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Electronic Park Brake Release Relay > Page 11621 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Electronic Park Brake Release Relay C2244 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Diagrams > Electronic Park Brake Release Relay > Page 11624 C2245 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Testing and Inspection > Electronic Park Brake Release Relay Parking Lamp Relay: Testing and Inspection Electronic Park Brake Release Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Testing and Inspection > Electronic Park Brake Release Relay > Page 11627 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Testing and Inspection > Electronic Park Brake Release Relay > Page 11628 Parking Lamp Relay: Testing and Inspection Electronic Park Brake Reset Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Testing and Inspection > Electronic Park Brake Release Relay > Page 11629 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 11634 C1474 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 11635 Backup Lamp Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 11636 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations Battery Discharge Protection Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 11640 View 151-1 (Engine Compartment) The battery savar relay is part of the central junction box (CJB) and is Not Serviceable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations Courtesy Lamp Relay: Locations View 151-12 (Dash Panel) The interior lamp relay is located in the instrument cluster and is Not Serviceable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Daytime Running Lamps (DRL) Headlamp Relay Daytime Running Lamp Relay: Locations Daytime Running Lamps (DRL) Headlamp Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Daytime Running Lamps (DRL) Headlamp Relay > Page 11648 View 151-1 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Daytime Running Lamps (DRL) Headlamp Relay > Page 11649 Daytime Running Lamp Relay: Locations Daytime Running Lamps (DRL) Ignition Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Daytime Running Lamps (DRL) Headlamp Relay > Page 11650 View 151-1 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Daytime Running Lamps (DRL) Headlamp Relay C1359 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Daytime Running Lamps (DRL) Headlamp Relay > Page 11653 C1171 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Daytime Running Lamps (DRL) Headlamp Relay Daytime Running Lamp Relay: Testing and Inspection Daytime Running Lamps (DRL) Headlamp Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Daytime Running Lamps (DRL) Headlamp Relay > Page 11656 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Daytime Running Lamps (DRL) Headlamp Relay > Page 11657 Daytime Running Lamp Relay: Testing and Inspection Daytime Running Lamps (DRL) Ignition Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Testing and Inspection > Daytime Running Lamps (DRL) Headlamp Relay > Page 11658 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 11662 C2241 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 11663 Fog/Driving Lamp Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 11664 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Page 11668 C2047 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Page 11669 Hazard Flasher Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Locations > Page 11670 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations > Page 11674 C2242 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations > Page 11675 High Beam Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations > Page 11676 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 11680 View 151-1 (Engine Compartment) The horn relay is part of the central junction box (CJB) and is Not Serviceable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations Interior Lighting Relay: Locations View 151-12 (Dash Panel) The interior lamp relay is located in the instrument cluster and is Not Serviceable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Electronic Park Brake Release Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Electronic Park Brake Release Relay > Page 11688 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Electronic Park Brake Release Relay C2244 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Diagrams > Electronic Park Brake Release Relay > Page 11691 C2245 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Testing and Inspection > Electronic Park Brake Release Relay Parking Lamp Relay: Testing and Inspection Electronic Park Brake Release Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Testing and Inspection > Electronic Park Brake Release Relay > Page 11694 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Testing and Inspection > Electronic Park Brake Release Relay > Page 11695 Parking Lamp Relay: Testing and Inspection Electronic Park Brake Reset Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Testing and Inspection > Electronic Park Brake Release Relay > Page 11696 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 11701 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Trailer Tow Relay, Parking Lamp C2240 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Trailer Tow Relay, Parking Lamp > Page 11704 C2110 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 11707 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 11708 Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Battery Charge Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 11709 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations > Page 11713 C2047 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations > Page 11714 Turn Signal Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations > Page 11715 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Service and Repair Ambient Light Sensor: Service and Repair LIGHT SENSOR Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Service and Repair > Page 11720 Removal and Installation Expedition 1. Remove the light sensor and bezel as an assembly from the defroster grille. - Disconnect the electrical connector. 2. Remove the 2 screws and the light sensor. Navigator 3. Remove the defroster grille. 4. Remove the 2 screws and the light sensor. - Disconnect the electrical connector. All vehicles 5. To install, reverse the removal procedure Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations View 151-6 (Transmission - 4R75E Without Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 11724 View 151-7 (Transmission - 4R75E With Four-wheel Drive) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 11725 C167 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations View 151-10 (behind Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 11729 C278 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 11730 Brake Light Switch: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - BPP switch is hardwired to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - BPP switch is hardwired to the Anti-Lock Brake System (ABS) Module, Lighting Control Module (LCM), or Rear Electronic Module (REM), the BPP signal is then broadcast over the network to be received by the PCM. - BPP switch is hardwired to the anti-lock brake system (ABS) traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 11731 Brake Light Switch: Service and Repair STOPLAMP SWITCH Removal and Installation 1. Disconnect the stoplamp switch electrical connector. 2. Remove the self-locking pin. 3. Remove the stoplamp switch from the brake booster push rod and the brake pedal assembly. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear View 151-30 (Left Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 11736 View 151-28 (Driver Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 11737 View 151-29 (Passenger Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 11738 View 151-31 (Right Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Rear > Page 11739 View 151-32 (Liftgate) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch C479 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 11742 C526 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 11743 C602 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 11744 C715 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 11745 C820 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 11746 Door Switch: Service and Repair DOOR AJAR SWITCH Removal and Installation 1. Remove the door lock actuator. 2. Release the locking tab and remove the door ajar switch. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection Hazard Warning Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 11750 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 11751 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations View 151-14 (Steering Column) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 11755 Headlamp Dimmer Switch: Diagrams C202a C202b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 11756 C202c Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 11757 Headlamp Dimmer Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 11758 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations View 151-12 (Dash Panel) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 11762 Headlamp Switch: Diagrams C205a C205b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 11763 C205c Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Testing and Inspection > Main Light Switch, Exterior Lamps Headlamp Switch: Testing and Inspection Main Light Switch, Exterior Lamps Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Testing and Inspection > Main Light Switch, Exterior Lamps > Page 11766 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Testing and Inspection > Main Light Switch, Exterior Lamps > Page 11767 Headlamp Switch: Testing and Inspection Main Light Switch, Interior Lamps Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Testing and Inspection > Main Light Switch, Exterior Lamps > Page 11768 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Testing and Inspection > Page 11769 Headlamp Switch: Service and Repair HEADLAMP SWITCH Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Testing and Inspection > Page 11770 Removal and Installation Expedition 1. CAUTION: Cover the end of the tool with tape to prevent damage to the trim panel. NOTE: Use a thin-bladed tool to remove the headlamp switch bezel assembly. Remove the headlamp switch and bezel assembly. Disconnect the electrical connectors. Navigator 2. Remove the instrument panel finish panel. 3. NOTE: Release the tabs to remove the headlamp switch. Remove the 2 screws and the headlamp switch. All vehicles 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) 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 INTERIOR LAMP SWITCH Removal and Installation 1. Remove the door trim panel. 2. Remove the interior lamp switch. 1 Disconnect the electrical connector. 2 Rotate the interior lamp switch one-quarter turn counterclockwise and remove. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations View 151-14 (Steering Column) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 11777 Turn Signal Switch: Diagrams C202a C202b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 11778 C202c Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion Turn Signal Switch: Testing and Inspection Multifunction Switch, Lamp Portion Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion > Page 11781 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion > Page 11782 Turn Signal Switch: Testing and Inspection Multifunction Switch, Turn Portion Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion > Page 11783 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion > Page 11784 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 11785 Turn Signal Switch: Service and Repair Steering Column Multifunction Switch Removal and Installation Steering Column Steering Column 1. Remove the steering wheel. 2. NOTE: Lower tilt release handle to access the second screw. Remove the lower steering column shroud. ^ Remove the screws. 3. NOTE: The screw is located behind the multi-function switch. Remove the screw and the upper steering column shroud. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 11786 4. Remove the bolt, push the release and raise the switch. 5. NOTE: A small screwdriver will be required to depress the connector release tab on connector number 2. Remove the multi-function switch. ^ Disconnect the 3 multi-function switch electrical connectors. ^ Remove the switch. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions Tail Lamp: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11791 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11792 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11793 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11794 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11795 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11796 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11797 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11798 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11799 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11800 Tail Lamp: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11801 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11802 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11803 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11804 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11805 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11806 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11807 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11808 Tail Lamp: Connector Views C412 C415 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11809 Tail Lamp: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 92-1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11810 92-2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11811 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. See: Diagrams/Components/Component Location Views Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions Trailer Lamps: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11816 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11817 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11818 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11819 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11820 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11821 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11822 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11823 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11824 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11825 Trailer Lamps: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11826 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11827 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11828 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11829 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11830 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11831 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11832 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11833 Trailer Lamps: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 95-1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11834 95-2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 11835 95-3 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. See: Diagrams/Components/Component Location Views Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Trailer Lamps: Initial Inspection and Diagnostic Overview INSPECTION AND VERIFICATION 1. Verify the customer concern. 2. Verify the exterior lighting system of the vehicle is operating correctly. If not, refer to the appropriate pinpoint test. See: Pinpoint Tests 3. Visually inspect the following for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical Central junction box (CJB) fuse(s): 10 (20A) (trailer tow parking lamps relay, trailer tow reversing lamps relay) - 13 (10A) (trailer tow battery charge relay coil) - 29 (30A) (trailer tow electric brake controller) - 36 (10A) (trailer tow RH stop/turn lamp) - 42 (10A) (trailer tow LH stop/turn lamp) - 106 (30A) (trailer tow battery charge relay) - Circuitry - Trailer - Trailer tow battery charge relay - Trailer tow parking lamps relay - Trailer tow reversing lamps relay - Trailer tow electric brake controller - CJB 4. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 5. If the concern is not visually evident, verify the symptom and GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11838 Trailer Lamps: Symptom Related Diagnostic Procedures Symptom Chart (Part 1) Symptom Chart (Part 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11839 Trailer Lamps: Pinpoint Tests Test V: The Trailer Lamps Are Inoperative PINPOINT TEST V: THE TRAILER LAMPS ARE INOPERATIVE V1 Normal Operation Ground for the trailer tow lamps is provided through circuit 206 (WH). Possible Causes - Circuit 206 (WH) open - Trailer Test W: The Individual Trailer Lamp Is Inoperative - RH Trailer Turn/Stop Lamp PINPOINT TEST W: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - RH TRAILER TURN/STOP LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11840 W1-W2 Normal Operation Voltage for the trailer tow RH turn/stop lamp is provided by the central junction box (CJB) fuse 36 (10A) through circuit 64 (DG). Possible Causes - Fuse - Circuit 64 (DG) open - Trailer - CJB Test X: The Individual Trailer Lamp Is Inoperative - LH Trailer Turn/Stop Lamp PINPOINT TEST X: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - LH TRAILER TURN/STOP LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11841 X1-X2 Normal Operation Voltage for the trailer tow LH turn/stop lamp is provided by the central junction box (CJB) fuse 42 (10A) through circuit 52 (YE). Possible Causes - Fuse - Circuit 52 (YE) open - Trailer - CJB Test Y: The Trailer Lamps Are Inoperative - Trailer Parking Lamps PINPOINT TEST Y: THE TRAILER LAMPS ARE INOPERATIVE - TRAILER PARKING LAMPS Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11842 Y1-Y4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11843 Y4-Y6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11844 Y7 Normal Operation Voltage for the trailer tow parking lamps relay coil is supplied through circuit 14 (BN) when the vehicle parking lamps are on. Ground for the trailer tow parking lamps relay coil is supplied through circuit 57 (BK). Voltage for the trailer tow parking lamps relay supply is sent by the central junction box (CJB) fuse 10 (20A). When the trailer tow parking lamps relay is energized, voltage is routed to the trailer through circuit 962 (BN/WH). Possible Causes - Fuse - Circuit 14 (BN) open - Circuit 57 (BK) open - Circuit 962 (BN/WH) open - Trailer - Trailer tow parking lamps relay - CJB Test Z: The Trailer Lamps Are Inoperative - Trailer Reversing Lamps PINPOINT TEST Z: THE TRAILER LAMPS ARE INOPERATIVE - TRAILER REVERSING LAMPS Z1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11845 Z1-Z3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11846 Z3-Z4 Normal Operation The trailer tow reversing lamps relay is integral to the central junction box (CJB). Voltage for the trailer tow reversing lamps relay coil is supplied through circuit 140 (BK/PK) when the vehicle reversing lamps are on. Ground for the trailer tow reversing lamps relay coil is supplied through circuit 57 (BK). Voltage for the trailer tow reversing lamps relay supply is sent by the CJB fuse 10 (20A). When the trailer tow reversing lamps relay is energized, voltage is routed to the trailer through circuit 963 (BK/LG). Possible Causes - Fuse - Circuit 140 (BK/PK) open - Circuit 57 (BK) open - Circuit 963 (BK/LG) open - Trailer - CJB Tests AA: The Trailer Lamps Are On Continuously PINPOINT TEST AA: THE TRAILER LAMPS ARE ON CONTINUOUSLY Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11847 AA1-AA4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11848 AA4 Continued Normal Operation - Trailer Tow Parking Lamps When the trailer tow parking lamps relay is energized, the voltage is routed to the trailer through circuit 962 (BN/WH). Normal Operation - Trailer Tow Reversing Lamps The trailer tow reversing lamps relay is integral to the central junction box (CJB). When the trailer tow reversing lamps relay is energized, voltage is routed to the trailer through circuit 963 (BK/LG). Possible Causes - Circuit 962 (BN/WH) short to voltage - Circuit 963 (BK/LG) short to voltage - Trailer tow parking lamps relay - Trailer - CJB Tests AB: The Trailer Battery Charging Is Inoperative PINPOINT TEST AB: THE TRAILER BATTERY CHARGING IS INOPERATIVE AB1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11849 AB1-AB2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11850 AB3-AB5 Normal Operation Voltage for the trailer tow battery charge relay coil is supplied by the central junction box (CJB) fuse 13 (10A) when the ignition switch is in the RUN position. Ground for the trailer tow battery charge relay coil is supplied through circuit 57 (BK). Voltage for the trailer tow battery charge relay supply is supplied by the CJB fuse 106 (30A). When the trailer tow battery charge relay is energized, voltage is routed to the trailer through circuit 49 (OG). Possible Causes - Fuse - Circuit 49 (OG) open - Circuit 57 (BK) open - Trailer tow battery charge relay - Trailer - CJB Tests AC: The Trailer Electric Brakes Do Not Operate Correctly PINPOINT TEST AC: THE TRAILER ELECTRIC BRAKES DO NOT OPERATE CORRECTLY Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11851 AC1-AC2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11852 AC2-AC4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11853 AC5-AC6 Normal Operation Voltage for the trailer tow electric brake controller is supplied by the central junction box (CJB) fuse 29 (30A) through circuit 50 (RD). Ground for the trailer tow electric brake controller coil is supplied through circuit 206 (WH). Voltage input from the stoplamp switch is supplied through circuit 511 (LG). When the parking lamps are on, voltage for the trailer tow electric brake controller illumination is supplied through circuit 14 (BN). Voltage output from the trailer tow electric brake controller voltage to the trailer is sent through circuit 43 (DB). Possible Causes - Fuse - Circuit 14 (BN) open - Circuit 43 (DB) open or short to ground - Circuit 50 (RD) open - Circuit 206 (WH) open - Circuit 511 (LG) open - Trailer tow electric brake controller - Trailer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Page 11854 Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Trailer Tow Relay, Battery Charge > Page 11859 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Trailer Tow Relay, Parking Lamp C2240 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Trailer Tow Relay, Parking Lamp > Page 11862 C2110 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 11865 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 11866 Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Battery Charge Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Testing and Inspection > Trailer Tow Relay, Parking Lamp > Page 11867 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Park/Turn Lamp, Left Front C1023 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Park/Turn Lamp, Left Front > Page 11873 C4032 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Park/Turn Lamp, Left Front > Page 11874 C1043 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Park/Turn Lamp, Left Front > Page 11875 C4035 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Page 11876 Turn Signal Lamp: Service and Repair SIDE TURN SIGNAL LAMP - SIGNAL MIRROR Removal and Installation 1. Release the 2 tabs and remove the mirror glass. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Page 11877 2. CAUTION: Take care not to break the tabs. Failure to follow these instructions may result in damage to the mirror. Slide the lamp assembly away from the vehicle, release the tabs and remove the signal mirror lamp assembly. Separate the bulb holders from the lamp assembly. 3. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Locations > Page 11881 C2047 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Locations > Page 11882 Turn Signal Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Locations > Page 11883 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations View 151-14 (Steering Column) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 11887 Turn Signal Switch: Diagrams C202a C202b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 11888 C202c Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion Turn Signal Switch: Testing and Inspection Multifunction Switch, Lamp Portion Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion > Page 11891 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion > Page 11892 Turn Signal Switch: Testing and Inspection Multifunction Switch, Turn Portion Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion > Page 11893 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Multifunction Switch, Lamp Portion > Page 11894 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Page 11895 Turn Signal Switch: Service and Repair Steering Column Multifunction Switch Removal and Installation Steering Column Steering Column 1. Remove the steering wheel. 2. NOTE: Lower tilt release handle to access the second screw. Remove the lower steering column shroud. ^ Remove the screws. 3. NOTE: The screw is located behind the multi-function switch. Remove the screw and the upper steering column shroud. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Page 11896 4. Remove the bolt, push the release and raise the switch. 5. NOTE: A small screwdriver will be required to depress the connector release tab on connector number 2. Remove the multi-function switch. ^ Disconnect the 3 multi-function switch electrical connectors. ^ Remove the switch. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Vanity Mirror Lamp, Left C907 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Vanity Mirror Lamp, Left > Page 11901 C906 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 11907 C2021 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 11908 Heated Glass Element Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 11909 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 11914 C2021 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 11915 Heated Glass Element Relay: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 11916 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Accessory Delay Relay Power Window Relay: Locations Accessory Delay Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Accessory Delay Relay > Page 11921 View 151-1 (Engine Compartment) The accessory delay relay is located in the central junction box, in the engine compartment, RH side. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Accessory Delay Relay > Page 11922 Power Window Relay: Locations Quarter Window Open Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Accessory Delay Relay > Page 11923 View 151-21 (Right Rear) The quarter window open relay is located in the auxiliary relay box 2, behind trim panel, in loading space, RH side. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Accessory Delay Relay > Page 11924 Power Window Relay: Locations Quarter Window Close Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Accessory Delay Relay > Page 11925 View 151-21 (Right Rear) The quarter window close relay is located in the auxiliary relay box 2, behind trim panel, in loading space, RH side. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Quarter Window Open Relay C4175 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Quarter Window Open Relay > Page 11928 C4176 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Open Relay Power Window Relay: Testing and Inspection Quarter Window Open Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Open Relay > Page 11931 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Open Relay > Page 11932 Power Window Relay: Testing and Inspection Quarter Window Close Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Open Relay > Page 11933 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch View 151-28 (Driver Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 11939 View 151-29 (Passenger Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 11940 View 151-30 (Left Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 11941 View 151-31 (Right Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 11942 View 151-23 (Roof) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch Power Window Switch: Diagrams Master Window Adjust Switch C504a C504b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 11945 C3193a C3193b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 11946 Power Window Switch: Diagrams Window Adjust Switch, Left Rear C701 C717 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 11947 Power Window Switch: Diagrams Window Adjust Switch, Right Rear C801 C819 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 11948 C624 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 11949 Power Window Switch: Diagrams Power Quarter Window Switch C998 C999 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch Power Window Switch: Testing and Inspection Master Window Adjust Switch Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 11952 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 11953 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 11954 Power Window Switch: Testing and Inspection Power Quarter Window Switch Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 11955 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 11956 Power Window Switch: Testing and Inspection Power Window Switch, RH Side Front Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 11957 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 11958 Power Window Switch: Testing and Inspection Window Adjust Switch Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 11959 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 11960 Power Window Switch: Service and Repair WINDOW CONTROL SWITCH Removal and Installation Navigator front 1. Lift up on the center console armrest. 2. Remove the center console window control switch panel. - Remove the pin-type retainer. 3. Disconnect the electrical connectors and remove the window control switch. - Release the locking tabs. Expedition front and Expedition passenger rear NOTE: Driver side Expedition shown, all others similar. 4. Remove the window control switch panel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 11961 5. Disconnect the electrical connector(s) and remove the window control switch. - Release the locking tabs. Navigator passenger rear 6. Remove the rear door trim panel. 7. Remove the window control switch from the door trim panel. All vehicles 8. To install, reverse removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Locations > Left Front View 151-28 (Driver Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Locations > Left Front > Page 11968 View 151-29 (Passenger Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Diagrams > Left Front Front Door Window Motor: Diagrams Left Front C518 C540 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Diagrams > Left Front > Page 11971 C608 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Quarter Window Motor > Component Information > Locations > LH Side Rear View 151-19 (Left Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Quarter Window Motor > Component Information > Locations > LH Side Rear > Page 11976 View 151-21 (Right Rear) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Quarter Window Motor > Component Information > Diagrams > LH Side Rear C4047 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Quarter Window Motor > Component Information > Diagrams > LH Side Rear > Page 11979 C4090 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Accessory Delay Relay Power Window Relay: Locations Accessory Delay Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Accessory Delay Relay > Page 11984 View 151-1 (Engine Compartment) The accessory delay relay is located in the central junction box, in the engine compartment, RH side. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Accessory Delay Relay > Page 11985 Power Window Relay: Locations Quarter Window Open Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Accessory Delay Relay > Page 11986 View 151-21 (Right Rear) The quarter window open relay is located in the auxiliary relay box 2, behind trim panel, in loading space, RH side. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Accessory Delay Relay > Page 11987 Power Window Relay: Locations Quarter Window Close Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Accessory Delay Relay > Page 11988 View 151-21 (Right Rear) The quarter window close relay is located in the auxiliary relay box 2, behind trim panel, in loading space, RH side. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Diagrams > Quarter Window Open Relay C4175 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Diagrams > Quarter Window Open Relay > Page 11991 C4176 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Open Relay Power Window Relay: Testing and Inspection Quarter Window Open Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Open Relay > Page 11994 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Open Relay > Page 11995 Power Window Relay: Testing and Inspection Quarter Window Close Relay Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and Inspection > Quarter Window Open Relay > Page 11996 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Master Window Adjust Switch View 151-28 (Driver Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 12001 View 151-29 (Passenger Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 12002 View 151-30 (Left Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 12003 View 151-31 (Right Rear Door) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 12004 View 151-23 (Roof) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch Power Window Switch: Diagrams Master Window Adjust Switch C504a C504b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 12007 C3193a C3193b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 12008 Power Window Switch: Diagrams Window Adjust Switch, Left Rear C701 C717 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 12009 Power Window Switch: Diagrams Window Adjust Switch, Right Rear C801 C819 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 12010 C624 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 12011 Power Window Switch: Diagrams Power Quarter Window Switch C998 C999 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch Power Window Switch: Testing and Inspection Master Window Adjust Switch Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 12014 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 12015 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 12016 Power Window Switch: Testing and Inspection Power Quarter Window Switch Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 12017 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 12018 Power Window Switch: Testing and Inspection Power Window Switch, RH Side Front Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 12019 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 12020 Power Window Switch: Testing and Inspection Window Adjust Switch Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 12021 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Page 12022 Power Window Switch: Service and Repair WINDOW CONTROL SWITCH Removal and Installation Navigator front 1. Lift up on the center console armrest. 2. Remove the center console window control switch panel. - Remove the pin-type retainer. 3. Disconnect the electrical connectors and remove the window control switch. - Release the locking tabs. Expedition front and Expedition passenger rear NOTE: Driver side Expedition shown, all others similar. 4. Remove the window control switch panel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Page 12023 5. Disconnect the electrical connector(s) and remove the window control switch. - Release the locking tabs. Navigator passenger rear 6. Remove the rear door trim panel. 7. Remove the window control switch from the door trim panel. All vehicles 8. To install, reverse removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Service and Repair > Front Door Glass, Frames and Mechanisms - Exploded View Window Frame: Service and Repair Front Door Glass, Frames and Mechanisms - Exploded View FRONT DOOR GLASS, FRAMES AND MECHANISMS - EXPLODED VIEW Removal and Installation 1. For additional information, refer to the procedures. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Service and Repair > Front Door Glass, Frames and Mechanisms - Exploded View > Page 12028 Window Frame: Service and Repair Front Door Glass Top Run FRONT DOOR GLASS TOP RUN Removal and Installation 1. Remove the front door window glass. 2. Remove the inside glass weatherstrip. 3. Remove the front door glass channel bolt and front door glass top run. - To install, tighten to 11 Nm (8 lb-ft). 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Service and Repair > Front Door Glass, Frames and Mechanisms - Exploded View > Page 12029 Window Frame: Service and Repair Rear Door Glass, Frames and Mechanisms - Exploded View REAR DOOR GLASS, FRAMES AND MECHANISMS - EXPLODED VIEW Removal and Installation 1. For additional information, refer to the procedures. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Service and Repair > Front Door Glass, Frames and Mechanisms - Exploded View > Page 12030 Window Frame: Service and Repair Rear Door Glass Top Run REAR DOOR GLASS TOP RUN Removal and Installation 1. Lower the rear door window glass. 2. Remove the rear door trim panel. 3. Remove the inside glass weatherstrip. 4. Remove the rear door glass channel bolts. - To install, tighten to 11 Nm (8 lb-ft). 5. Remove the rear door glass top run. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Glass: > 07-10-5 > May > 07 > Body Front Door Window Scratched Front Door Window Glass: Customer Interest Body - Front Door Window Scratched TSB 07-10-5 05/28/07 FRONT DOOR SIDE GLASS SCRATCHED DUE TO COLLECTION OF DIRT/DEBRIS IN WARPED OUTER WINDOW MOLDING FORD: 2003-2007 Expedition 2005 Excursion 2005-2008 F-Super Duty LINCOLN: 2007 Navigator This article supersedes TSB 06-18-2 to update the vehicle model years, vehicle application and parts information. ISSUE Some 2005-2008 F-Super Duty, 2005 Excursion, 2003-2007 Expedition and 2007 Navigator vehicles may exhibit outer window molding weather strip assembly warping around the lower front window channel. The condition may be described as a warped or loose outer window molding. There may be a pucker or gap between the window beltline molding weather strip assembly and the window glass. This may result in dirt and debris collecting between the molding and the glass, and therefore scratching the side-window glass. ACTION Use the Service Procedure to replace the outer window molding and adjust the molding flange. SERVICE PROCEDURE 1. Lower the side door window completely. 2. Remove the outside mirror. 3. Remove the outer window molding weather strip assembly by lifting it up away from the flange (Figure 1). 4. Raise the side door glass completely. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Glass: > 07-10-5 > May > 07 > Body Front Door Window Scratched > Page 12040 5. Measure the distance from inboard sur[ace of the door molding flange to outboard surface of the window glass (Figure 2). Distance from flange to glass should be between 5/8-3/4" (16-19 mm) for F-Super Duty and Excursion, and 3/16-7/16" (5-11 mm) for Expedition and Navigator. 6. Lower glass completely. 7. Adjust the door molding flange to meet the 5/8-3/4" (16-19 mm) dimension. Do not adjust flange more than 3/4" (19 mm) away from the glass. 8. Install a new lower window molding weather strip assembly. 9. Reinstall mirror. 10. If the side door glass has been scratched, replace the glass. Refer to Workshop Manual, Section 501-11. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Glass: > 07-10-5 > May > 07 > Body Front Door Window Scratched > Page 12041 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071005A 2005-2008 F-Super Duty, 0.5 Hr. 2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005B 2005-2008 F-Super Duty, 0.9 Hr. 2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange Both Front Doors (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005C 2005-2008 F-Super Duty, 0.7 Hr. 2005 Excursion: Replace The Window Beltline Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Glass: > 07-10-5 > May > 07 > Body Front Door Window Scratched > Page 12042 Molding Includes Time To Measure And Adjust Door Molding Flange, And Replace Window Glass: One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005D 2005-2008 F-Super Duty, 1.3 Hrs. 2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange, And Replace Window Glass Both Front Doors (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005E 2003-2007 Expedition, 0.6 Hr. 2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust Door Molding Flange: One Front Door (Do Not Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) 07100SF 2003-2007 Expedition, 1.1 Hrs. 2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust Door Molding Flange: Both Front Doors (Do Not Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) 071005G 2003-2007 Expedition, 0.9 Hr. 2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust Door Molding Flange And Replace Window Glass: One Front Door (Do Not Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) 071005H 2003-2007 Expedition, 1.7 Hrs. 2007 Navigator: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange And Replace Window Glass: Both Front Doors (Do Not Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Glass: > 07-10-5 > May > 07 > Body Front Door Window Scratched > Page 12043 Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) DEALER CODING CONDITION BASIC PART NO. CODE 2521452 07 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 07-10-5 > May > 07 > Body - Front Door Window Scratched Front Door Window Glass: All Technical Service Bulletins Body - Front Door Window Scratched TSB 07-10-5 05/28/07 FRONT DOOR SIDE GLASS SCRATCHED DUE TO COLLECTION OF DIRT/DEBRIS IN WARPED OUTER WINDOW MOLDING FORD: 2003-2007 Expedition 2005 Excursion 2005-2008 F-Super Duty LINCOLN: 2007 Navigator This article supersedes TSB 06-18-2 to update the vehicle model years, vehicle application and parts information. ISSUE Some 2005-2008 F-Super Duty, 2005 Excursion, 2003-2007 Expedition and 2007 Navigator vehicles may exhibit outer window molding weather strip assembly warping around the lower front window channel. The condition may be described as a warped or loose outer window molding. There may be a pucker or gap between the window beltline molding weather strip assembly and the window glass. This may result in dirt and debris collecting between the molding and the glass, and therefore scratching the side-window glass. ACTION Use the Service Procedure to replace the outer window molding and adjust the molding flange. SERVICE PROCEDURE 1. Lower the side door window completely. 2. Remove the outside mirror. 3. Remove the outer window molding weather strip assembly by lifting it up away from the flange (Figure 1). 4. Raise the side door glass completely. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 07-10-5 > May > 07 > Body - Front Door Window Scratched > Page 12049 5. Measure the distance from inboard sur[ace of the door molding flange to outboard surface of the window glass (Figure 2). Distance from flange to glass should be between 5/8-3/4" (16-19 mm) for F-Super Duty and Excursion, and 3/16-7/16" (5-11 mm) for Expedition and Navigator. 6. Lower glass completely. 7. Adjust the door molding flange to meet the 5/8-3/4" (16-19 mm) dimension. Do not adjust flange more than 3/4" (19 mm) away from the glass. 8. Install a new lower window molding weather strip assembly. 9. Reinstall mirror. 10. If the side door glass has been scratched, replace the glass. Refer to Workshop Manual, Section 501-11. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 07-10-5 > May > 07 > Body - Front Door Window Scratched > Page 12050 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071005A 2005-2008 F-Super Duty, 0.5 Hr. 2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005B 2005-2008 F-Super Duty, 0.9 Hr. 2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange Both Front Doors (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005C 2005-2008 F-Super Duty, 0.7 Hr. 2005 Excursion: Replace The Window Beltline Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 07-10-5 > May > 07 > Body - Front Door Window Scratched > Page 12051 Molding Includes Time To Measure And Adjust Door Molding Flange, And Replace Window Glass: One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005D 2005-2008 F-Super Duty, 1.3 Hrs. 2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange, And Replace Window Glass Both Front Doors (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005E 2003-2007 Expedition, 0.6 Hr. 2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust Door Molding Flange: One Front Door (Do Not Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) 07100SF 2003-2007 Expedition, 1.1 Hrs. 2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust Door Molding Flange: Both Front Doors (Do Not Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) 071005G 2003-2007 Expedition, 0.9 Hr. 2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust Door Molding Flange And Replace Window Glass: One Front Door (Do Not Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) 071005H 2003-2007 Expedition, 1.7 Hrs. 2007 Navigator: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange And Replace Window Glass: Both Front Doors (Do Not Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 07-10-5 > May > 07 > Body - Front Door Window Scratched > Page 12052 Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) DEALER CODING CONDITION BASIC PART NO. CODE 2521452 07 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 12053 Front Door Window Glass: By Symptom Technical Service Bulletin # 07-10-5 Date: 070528 Body - Front Door Window Scratched TSB 07-10-5 05/28/07 FRONT DOOR SIDE GLASS SCRATCHED DUE TO COLLECTION OF DIRT/DEBRIS IN WARPED OUTER WINDOW MOLDING FORD: 2003-2007 Expedition 2005 Excursion 2005-2008 F-Super Duty LINCOLN: 2007 Navigator This article supersedes TSB 06-18-2 to update the vehicle model years, vehicle application and parts information. ISSUE Some 2005-2008 F-Super Duty, 2005 Excursion, 2003-2007 Expedition and 2007 Navigator vehicles may exhibit outer window molding weather strip assembly warping around the lower front window channel. The condition may be described as a warped or loose outer window molding. There may be a pucker or gap between the window beltline molding weather strip assembly and the window glass. This may result in dirt and debris collecting between the molding and the glass, and therefore scratching the side-window glass. ACTION Use the Service Procedure to replace the outer window molding and adjust the molding flange. SERVICE PROCEDURE 1. Lower the side door window completely. 2. Remove the outside mirror. 3. Remove the outer window molding weather strip assembly by lifting it up away from the flange (Figure 1). 4. Raise the side door glass completely. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 12054 5. Measure the distance from inboard sur[ace of the door molding flange to outboard surface of the window glass (Figure 2). Distance from flange to glass should be between 5/8-3/4" (16-19 mm) for F-Super Duty and Excursion, and 3/16-7/16" (5-11 mm) for Expedition and Navigator. 6. Lower glass completely. 7. Adjust the door molding flange to meet the 5/8-3/4" (16-19 mm) dimension. Do not adjust flange more than 3/4" (19 mm) away from the glass. 8. Install a new lower window molding weather strip assembly. 9. Reinstall mirror. 10. If the side door glass has been scratched, replace the glass. Refer to Workshop Manual, Section 501-11. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 12055 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071005A 2005-2008 F-Super Duty, 0.5 Hr. 2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005B 2005-2008 F-Super Duty, 0.9 Hr. 2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange Both Front Doors (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005C 2005-2008 F-Super Duty, 0.7 Hr. 2005 Excursion: Replace The Window Beltline Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 12056 Molding Includes Time To Measure And Adjust Door Molding Flange, And Replace Window Glass: One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005D 2005-2008 F-Super Duty, 1.3 Hrs. 2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange, And Replace Window Glass Both Front Doors (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005E 2003-2007 Expedition, 0.6 Hr. 2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust Door Molding Flange: One Front Door (Do Not Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) 07100SF 2003-2007 Expedition, 1.1 Hrs. 2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust Door Molding Flange: Both Front Doors (Do Not Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) 071005G 2003-2007 Expedition, 0.9 Hr. 2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust Door Molding Flange And Replace Window Glass: One Front Door (Do Not Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) 071005H 2003-2007 Expedition, 1.7 Hrs. 2007 Navigator: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange And Replace Window Glass: Both Front Doors (Do Not Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 12057 Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) DEALER CODING CONDITION BASIC PART NO. CODE 2521452 07 Disclaimer Technical Service Bulletin # 07-10-5 Date: 070528 Body - Front Door Window Scratched TSB 07-10-5 05/28/07 FRONT DOOR SIDE GLASS SCRATCHED DUE TO COLLECTION OF DIRT/DEBRIS IN WARPED OUTER WINDOW MOLDING FORD: 2003-2007 Expedition 2005 Excursion 2005-2008 F-Super Duty LINCOLN: 2007 Navigator This article supersedes TSB 06-18-2 to update the vehicle model years, vehicle application and parts information. ISSUE Some 2005-2008 F-Super Duty, 2005 Excursion, 2003-2007 Expedition and 2007 Navigator vehicles may exhibit outer window molding weather strip assembly warping around the lower front window channel. The condition may be described as a warped or loose outer window molding. There may be a pucker or gap between the window beltline molding weather strip assembly and the window glass. This may result in dirt and debris collecting between the molding and the glass, and therefore scratching the side-window glass. ACTION Use the Service Procedure to replace the outer window molding and adjust the molding flange. SERVICE PROCEDURE 1. Lower the side door window completely. 2. Remove the outside mirror. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 12058 3. Remove the outer window molding weather strip assembly by lifting it up away from the flange (Figure 1). 4. Raise the side door glass completely. 5. Measure the distance from inboard sur[ace of the door molding flange to outboard surface of the window glass (Figure 2). Distance from flange to glass should be between 5/8-3/4" (16-19 mm) for F-Super Duty and Excursion, and 3/16-7/16" (5-11 mm) for Expedition and Navigator. 6. Lower glass completely. 7. Adjust the door molding flange to meet the 5/8-3/4" (16-19 mm) dimension. Do not adjust flange more than 3/4" (19 mm) away from the glass. 8. Install a new lower window molding weather strip assembly. 9. Reinstall mirror. 10. If the side door glass has been scratched, replace the glass. Refer to Workshop Manual, Section 501-11. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 12059 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071005A 2005-2008 F-Super Duty, 0.5 Hr. 2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005B 2005-2008 F-Super Duty, 0.9 Hr. 2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange Both Front Doors (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005C 2005-2008 F-Super Duty, 0.7 Hr. 2005 Excursion: Replace Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 12060 The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange, And Replace Window Glass: One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005D 2005-2008 F-Super Duty, 1.3 Hrs. 2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange, And Replace Window Glass Both Front Doors (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005E 2003-2007 Expedition, 0.6 Hr. 2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust Door Molding Flange: One Front Door (Do Not Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) 07100SF 2003-2007 Expedition, 1.1 Hrs. 2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust Door Molding Flange: Both Front Doors (Do Not Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) 071005G 2003-2007 Expedition, 0.9 Hr. 2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust Door Molding Flange And Replace Window Glass: One Front Door (Do Not Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) 071005H 2003-2007 Expedition, 1.7 Hrs. 2007 Navigator: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange And Replace Window Glass: Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 12061 Both Front Doors (Do Not Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) DEALER CODING CONDITION BASIC PART NO. CODE 2521452 07 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > Page 12062 Front Door Window Glass: Service and Repair FRONT DOOR WINDOW GLASS Removal and Installation All vehicles 1. Remove the front door trim panel. 2. Remove the front door weathershield. Expedition 3. NOTE: Driver side shown, passenger side similar. Connect the window control switch. All vehicles 4. Lower the window glass to access the 2 window glass to regulator bolts. 5. Remove the inside glass weatherstrip. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > Page 12063 6. Remove the front door glass channel bolt and position aside the channel. - To install, tighten to 11 Nm (8 lb-ft). 7. Remove the window glass-to-regulator bolts and front door window glass. - To install, tighten to 11 Nm (8 lb-ft). 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair LIFTGATE WINDOW GLASS Removal and Installation Window glass assembly 1. Remove the rear window wiper motor. 2. Disconnect the rear window defrost electrical connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Page 12067 3. CAUTION: - The liftgate glass must be supported when removing and installing the liftgate assist cylinders. - Do not extend the socket clips more than 2.0 mm (0.08 in) or failure of the socket can occur. Disconnect the 2 liftgate glass assist cylinders. 1 Insert a screwdriver blade under the socket clip and lift. 2 Gently pull the socket off the ball stud. Window glass assembly or hinge assembly 4. Remove the liftgate glass hinge-to-body fasteners and remove the glass. - To install, tighten to 12 Nm (9 lb-ft). Window hinge assembly 5. Remove the liftgate glass to hinge fasteners and remove the glass. - Apply Threadlock 262 to the liftgate glass to hinge fasteners during installation. - To install, tighten to 8 Nm (71 lb-in). Window glass assembly or window hinge assembly 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair Quarter Window Glass: Service and Repair REAR QUARTER WINDOW GLASS Removal All vehicles 1. Remove the rear quarter trim panel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Page 12071 2. CAUTION: To prevent damage to the coat hanger retainer, use a 3/16-inch flat-blade screwdriver for this step. Remove the front and rear coat hooks and lower the headliner over the rear quarter window glass. Open the access cover. - Insert a screwdriver into the coat hook slot and turn the screwdriver 90 degrees so that it engages in the plastic component slot. This will spread the steal attachment clip wings to allow the plastic component to disengage. Vehicles with power vent window 3. Remove the bolts and rear quarter window regulator motor. - Disconnect the electrical connector. 4. Disconnect the rear quarter window regulator. All vehicles 5. Disconnect the audio antenna. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Page 12072 6. If equipped, remove the air duct. - Remove the pin-type retainer. 7. CAUTION: Have an assistant hold the rear quarter window glass. Remove the rear quarter window glass. 1 Remove the nuts. 2 Remove the rear quarter window glass. 8. Remove the excess foam butyl from the window opening. Installation All vehicles 1. Apply 8 mm (0.32 in) Foam Butyl of equivalent meeting Ford specification WSB-M4GB45-A to the rear quarter window glass frame. - Start at the bottom middle and work around the frame. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Page 12073 2. Install the rear quarter window glass. 1 Position the rear quarter window glass. 2 Install the rear quarter window glass nuts. - Tighten to 2 Nm (18 lb-in). 3. If equipped, install the air duct. - Install the pin-type retainer. 4. Connect the audio antenna. Vehicles with power vent windows 5. Install the rear quarter window regulator. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Page 12074 6. Install the bolts and rear quarter window regulator motor. - Tighten to 9 Nm (80 lb-in). - Connect the electrical connector. All vehicles 7. Position the headliner and install the coat hooks. 8. Install the rear quarter trim panel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair > Rear Door Window Glass Rear Door Window Glass: Service and Repair Rear Door Window Glass REAR DOOR WINDOW GLASS Removal and Installation 1. Remove the rear door trim panel. 2. Position back the rear door weathershield. 3. Connect the window control switch. 4. Lower the window glass to access the 2 window glass to regulator bolts. 5. Remove the inside glass weatherstrip. 6. Remove the rear door glass channel bolts. - To install, tighten to 11 Nm (8 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair > Rear Door Window Glass > Page 12079 7. Remove the window glass to regulator bolts and rear door window glass. - To install, tighten to 11 Nm (8 lb-ft). 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair > Rear Door Window Glass > Page 12080 Rear Door Window Glass: Service and Repair Rear Door Window Glass - Stationary REAR DOOR WINDOW GLASS - STATIONARY Removal and Installation 1. Remove the rear door window glass. 2. Remove the rear door exterior glass moulding. 3. Remove the rear door glass top run. 4. Remove the rear door stationary glass screw. 5. Remove the stationary rear door glass. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair Front Door Window Regulator: Service and Repair WINDOW REGULATOR - FRONT DOOR Removal and Installation All vehicles 1. Remove the front door trim panel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Page 12085 2. Remove the screws and the front door speaker. - Disconnect the electrical connector. 3. Remove the front door weathershield. Expedition 4. NOTE: Driver side shown, passenger side similar. Connect the window control switch. All vehicles 5. Lower the window glass to access the 2 window glass-to-regulator bolts. Expedition Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Page 12086 6. NOTE: Driver side shown, passenger side similar. Disconnect the window control switch. All vehicles 7. Remove the window glass-to-regulator bolts and front door window glass. - To install, tighten to 11 Nm (8 lb-ft). 8. NOTE: Secure the front window glass in the full UP position. Secure the front window glass with tape to the front door frame. 9. Position the interior door handle aside. 1 Remove the cable conduit fitting from the carrier assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Page 12087 2 Lift upward on the interior door handle retaining bracket and pivot the interior door handle out of the bracket. 3 Remove the cable from the door handle. 10. Release the crash sensor harness pin-type retainers. 11. Position the front door window regulator harness aside. 1 Disconnect the electrical connectors. 2 Release the pin-type retainers. 12. Remove the front window regulator. 1 Loosen the 2 hanger bolts. 2 Remove the front window regulator bolts and front top run channel bolt. To install, tighten to 11 Nm (8 lb-ft). 13. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair Rear Door Window Regulator: Service and Repair WINDOW REGULATOR - REAR DOOR Removal and Installation 1. Remove the rear door trim panel. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Page 12091 2. Remove the rear door speaker. 1 Remove the screws. 2 Disconnect the electrical connector. 3 Remove the speaker. 3. Remove the rear door weathershield. 4. Connect the window control switch. 5. Lower the window glass to access the 2 window glass-to-regulator bolts. 6. Disconnect the window control switch. 7. Remove the window glass-to-regulator bolts and rear door window glass. - To install, tighten to 11 Nm (8 lb-ft). 8. NOTE: Secure the rear window glass in the full UP position. Secure the rear window glass with tape to the front door frame. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Page 12092 9. Disconnect the rear door window regulator electrical connectors. 10. Position the interior door handle aside. - Lift upward on the interior door handle retaining bracket and pivot the interior door handle out of the bracket. 11. Remove the rear door window regulator assembly. - Remove the bolts. To install, tighten to 11 Nm (8 lb-ft). 12. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest: > 07-10-5 > May > 07 > Body - Front Door Window Scratched Window Seal: Customer Interest Body - Front Door Window Scratched TSB 07-10-5 05/28/07 FRONT DOOR SIDE GLASS SCRATCHED DUE TO COLLECTION OF DIRT/DEBRIS IN WARPED OUTER WINDOW MOLDING FORD: 2003-2007 Expedition 2005 Excursion 2005-2008 F-Super Duty LINCOLN: 2007 Navigator This article supersedes TSB 06-18-2 to update the vehicle model years, vehicle application and parts information. ISSUE Some 2005-2008 F-Super Duty, 2005 Excursion, 2003-2007 Expedition and 2007 Navigator vehicles may exhibit outer window molding weather strip assembly warping around the lower front window channel. The condition may be described as a warped or loose outer window molding. There may be a pucker or gap between the window beltline molding weather strip assembly and the window glass. This may result in dirt and debris collecting between the molding and the glass, and therefore scratching the side-window glass. ACTION Use the Service Procedure to replace the outer window molding and adjust the molding flange. SERVICE PROCEDURE 1. Lower the side door window completely. 2. Remove the outside mirror. 3. Remove the outer window molding weather strip assembly by lifting it up away from the flange (Figure 1). 4. Raise the side door glass completely. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest: > 07-10-5 > May > 07 > Body - Front Door Window Scratched > Page 12101 5. Measure the distance from inboard sur[ace of the door molding flange to outboard surface of the window glass (Figure 2). Distance from flange to glass should be between 5/8-3/4" (16-19 mm) for F-Super Duty and Excursion, and 3/16-7/16" (5-11 mm) for Expedition and Navigator. 6. Lower glass completely. 7. Adjust the door molding flange to meet the 5/8-3/4" (16-19 mm) dimension. Do not adjust flange more than 3/4" (19 mm) away from the glass. 8. Install a new lower window molding weather strip assembly. 9. Reinstall mirror. 10. If the side door glass has been scratched, replace the glass. Refer to Workshop Manual, Section 501-11. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest: > 07-10-5 > May > 07 > Body - Front Door Window Scratched > Page 12102 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071005A 2005-2008 F-Super Duty, 0.5 Hr. 2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005B 2005-2008 F-Super Duty, 0.9 Hr. 2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange Both Front Doors (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005C 2005-2008 F-Super Duty, 0.7 Hr. 2005 Excursion: Replace The Window Beltline Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest: > 07-10-5 > May > 07 > Body - Front Door Window Scratched > Page 12103 Molding Includes Time To Measure And Adjust Door Molding Flange, And Replace Window Glass: One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005D 2005-2008 F-Super Duty, 1.3 Hrs. 2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange, And Replace Window Glass Both Front Doors (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005E 2003-2007 Expedition, 0.6 Hr. 2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust Door Molding Flange: One Front Door (Do Not Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) 07100SF 2003-2007 Expedition, 1.1 Hrs. 2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust Door Molding Flange: Both Front Doors (Do Not Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) 071005G 2003-2007 Expedition, 0.9 Hr. 2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust Door Molding Flange And Replace Window Glass: One Front Door (Do Not Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) 071005H 2003-2007 Expedition, 1.7 Hrs. 2007 Navigator: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange And Replace Window Glass: Both Front Doors (Do Not Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest: > 07-10-5 > May > 07 > Body - Front Door Window Scratched > Page 12104 Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) DEALER CODING CONDITION BASIC PART NO. CODE 2521452 07 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-10-5 > May > 07 > Body - Front Door Window Scratched Window Seal: All Technical Service Bulletins Body - Front Door Window Scratched TSB 07-10-5 05/28/07 FRONT DOOR SIDE GLASS SCRATCHED DUE TO COLLECTION OF DIRT/DEBRIS IN WARPED OUTER WINDOW MOLDING FORD: 2003-2007 Expedition 2005 Excursion 2005-2008 F-Super Duty LINCOLN: 2007 Navigator This article supersedes TSB 06-18-2 to update the vehicle model years, vehicle application and parts information. ISSUE Some 2005-2008 F-Super Duty, 2005 Excursion, 2003-2007 Expedition and 2007 Navigator vehicles may exhibit outer window molding weather strip assembly warping around the lower front window channel. The condition may be described as a warped or loose outer window molding. There may be a pucker or gap between the window beltline molding weather strip assembly and the window glass. This may result in dirt and debris collecting between the molding and the glass, and therefore scratching the side-window glass. ACTION Use the Service Procedure to replace the outer window molding and adjust the molding flange. SERVICE PROCEDURE 1. Lower the side door window completely. 2. Remove the outside mirror. 3. Remove the outer window molding weather strip assembly by lifting it up away from the flange (Figure 1). 4. Raise the side door glass completely. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-10-5 > May > 07 > Body - Front Door Window Scratched > Page 12110 5. Measure the distance from inboard sur[ace of the door molding flange to outboard surface of the window glass (Figure 2). Distance from flange to glass should be between 5/8-3/4" (16-19 mm) for F-Super Duty and Excursion, and 3/16-7/16" (5-11 mm) for Expedition and Navigator. 6. Lower glass completely. 7. Adjust the door molding flange to meet the 5/8-3/4" (16-19 mm) dimension. Do not adjust flange more than 3/4" (19 mm) away from the glass. 8. Install a new lower window molding weather strip assembly. 9. Reinstall mirror. 10. If the side door glass has been scratched, replace the glass. Refer to Workshop Manual, Section 501-11. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-10-5 > May > 07 > Body - Front Door Window Scratched > Page 12111 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071005A 2005-2008 F-Super Duty, 0.5 Hr. 2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005B 2005-2008 F-Super Duty, 0.9 Hr. 2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange Both Front Doors (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005C 2005-2008 F-Super Duty, 0.7 Hr. 2005 Excursion: Replace The Window Beltline Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-10-5 > May > 07 > Body - Front Door Window Scratched > Page 12112 Molding Includes Time To Measure And Adjust Door Molding Flange, And Replace Window Glass: One Front Door (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005D 2005-2008 F-Super Duty, 1.3 Hrs. 2005 Excursion: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange, And Replace Window Glass Both Front Doors (Do Not Use With 17628B, 17682C, 23943A, 23943B, 23943A14, 18808AF, 17682B) 071005E 2003-2007 Expedition, 0.6 Hr. 2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust Door Molding Flange: One Front Door (Do Not Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) 07100SF 2003-2007 Expedition, 1.1 Hrs. 2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust Door Molding Flange: Both Front Doors (Do Not Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) 071005G 2003-2007 Expedition, 0.9 Hr. 2007 Navigator: Replace The Window Beltline Molding, Includes Time To Measure And Adjust Door Molding Flange And Replace Window Glass: One Front Door (Do Not Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) 071005H 2003-2007 Expedition, 1.7 Hrs. 2007 Navigator: Replace The Window Beltline Molding Includes Time To Measure And Adjust Door Molding Flange And Replace Window Glass: Both Front Doors (Do Not Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-10-5 > May > 07 > Body - Front Door Window Scratched > Page 12113 Use With 17682C, 21452A, 23943A, 23943AB, 23943A14, 18808AF, 17682B) DEALER CODING CONDITION BASIC PART NO. CODE 2521452 07 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > 08-21-3 > Oct > 08 > A/C - Inoperative/Blows Warm Air Compressor Clutch: All Technical Service Bulletins A/C - Inoperative/Blows Warm Air TSB 08-21-3 10/27/08 A/C SYSTEM BLOWS WARM/INOPERATIVE - HIGH AMBIENT TEMPERATURES, EXTENDED IDLE TIMES, TRAILER TOW, DUSTY CLIMATES OR OFF ROAD USE FORD: 2006 Expedition LINCOLN: 2006 Navigator ISSUE Some 2006 Expedition and Navigator vehicles equipped with A/C may become inoperative or blow warm air due to an open electrical circuit of the A/C compressor field coil in high ambient temperatures, extended idle times, trailer tow, dusty climates or off road use. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Replace the A/C clutch disc, field coil and compressor pulley, using the part numbers below. The replacing parts are larger in diameter. Failure to use the part numbers listed below together may cause repeat failure. 1. Recover A/C refrigerant per Workshop Manual (WSM), Section 412-00. 2. Replace the A/C compressor clutch, field coil and pulley per WSM, Section 412-01. 3. Recharge A/C system per WSM, Section 412-00. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 082103A 2006 Expedition 4X2, 1.4 Hrs. Navigator 4X2/4X4: Replace the A/C compressor clutch, field coil and pulley, Includes Time To Remove and Install Compressor (Do Not Use With 19700A, 19700A4) 082103A 2006 Expedition 4X4: 1.6 Hrs. Replace the A/C compressor clutch, field coil and pulley, Includes Time To Remove and Install Compressor (Do Not Use With 19700A, 19700A4) DEALER CODING CONDITION BASIC PART NO. CODE 19D798 28 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > 08-21-3 > Oct > 08 > A/C - Inoperative/Blows Warm Air > Page 12119 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > 08-21-3 > Oct > 08 > A/C - Inoperative/Blows Warm Air > Page 12125 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield Reseal Windshield: Service and Repair Windshield Reseal WINDSHIELD RESEAL 1. Remove the cowl grille. 2. Remove the A-pillar trim panels. - Remove the bolt covers and bolts. 3. If equipped, remove the overhead console. 4. If equipped, remove the roof opening panel trim. 5. Remove the interior rear view mirror. 6. Remove the sun visors. 1 Remove the 4 screws. 2 Remove the 2 sun visor and visor arm clips. If equipped, disconnect the electrical connectors. 7. Partially lower the front portion of the headliner near the windshield upper opening and block with a suitable material. 8. Clean the edge formed by the existing urethane and the glass on the inside at the top and sides, and outside on the bottom of the windshield with an alcohol-free cleaner. 9. Cut the urethane applicator tip to specification. 10. NOTE: Use either a high-ratio electric or battery-operated caulk gun that will apply the urethane with less effort and a continuous bead. Apply a bead of Urethane Adhesive to the cleaned area. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield Reseal > Page 12130 11. NOTE: Make sure that all gaps in the urethane adhesive are smoothed into one continuous bead. Backfill the urethane application and clean the excess. 12. CAUTION: The urethane adhesive must cure for a minimum of one hour before testing for air or water leaks. After the urethane has cured, check the windshield seal for air or water leaks through the urethane adhesive bead and add urethane adhesive as necessary. 13. Install the headliner. 14. Install the sun visors. 1 Position the sun visors. 2 Install the 4 screws. If equipped, connect the electrical connectors. 15. Install the interior rear view mirror. 16. If equipped, install the roof opening panel trim. 17. If equipped, install the overhead console. 18. Install the A-pillar trim panels. - Install the bolts and covers. 19. Install the cowl grille. 20. Clean the interior and exterior of the windshield glass with an alcohol-free cleaner. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield Reseal > Page 12131 Windshield: Service and Repair Windshield Glass WINDSHIELD GLASS Special Tool(s) Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield Reseal > Page 12132 Removal WARNING: To prevent glass splinters from entering eyes or cutting hands, wear safety glasses and heavy gloves when cutting glass from the vehicle. 1. Remove the cowl grille. 2. Remove the A-pillar trim panels. - Remove the bolt covers and bolts. 3. If equipped, remove the overhead console. 4. Remove the interior rear view mirror. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield Reseal > Page 12133 5. Remove the sun visors. 1 Remove the 4 screws. 2 Remove the 2 sun visor and visor arm clips. If equipped, disconnect the electrical connectors. 6. Lower the front portion of the headliner. 7. Remove the windshield side mouldings. - Pull out starting at the top corner. 8. Remove the upper windshield weatherstrip. - Pull out starting at the corner. 9. Mark the outside of the windshield glass with a wax pencil to avoid damaging the glass stops when cutting the urethane. 10. Using a soft brush or vacuum, remove any dirt and foreign material from the pinch weld. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield Reseal > Page 12134 11. CAUTION: Care must be taken to avoid scratching the pinchweld. NOTE: Lubricate the urethane adhesive with water to aid the special tool while cutting. Using the special tool, cut the urethane adhesive from the windshield glass. Insert the blade into the urethane at the top middle of the glass and work toward the top corners. - Insert the blade at the top corners and work down each side of the glass toward the bottom. 12. CAUTION: Pump special tool 164-R2459 or equivalent slowly as cowl adhesive is cut to avoid breaking glass. Using the special tool, distance the windshield from the body. 13. NOTE: Removing the windshield glass requires an assistant. Using the special tool, cut the remaining urethane adhesive and remove the windshield glass. 14. Using a soft brush or vacuum, remove any dirt and foreign material from the pinch weld. Installation CAUTION: Do not drive the vehicle after installing windshield glass until the urethane adhesive has cured. Inadequate curing of the urethane adhesive adversely affects the strength of the urethane adhesive bond. 1. Dry-fit the windshield glass by centering it side-to-side and by adjusting the setting blocks (if equipped) to get the correct position of the part top to bottom. Make the alignment marks with tape or non-staining grease pencil on both the glass and the vehicle body. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield Reseal > Page 12135 2. CAUTION: Care must be taken to avoid scratching the pinch weld. Trim the remaining urethane adhesive on the pinch weld to within specification. The old urethane surface should be smooth and free of cuts and contamination. 3. If reinstalling the original windshield, remove excess urethane adhesive from the windshield glass. 4. If installing a new windshield glass, clean the inside of the glass surface with an alcohol-free cleaner to make sure the ceramic-coated area is clean. 5. CAUTION: Be sure to use the same brand and cure-rate products for the adhesive and primer. Do not mix different brands of urethane and primer. Refer to the Material Chart in this procedure. NOTE: Sika uses the same black primer for the glass and pinch weld area. If installing a new windshield glass, apply urethane glass primer according to manufacturer's instructions. Allow at least 6 minutes to dry. 6. Install the upper windshield weatherstrip. 7. Cut the urethane applicator tip to specification. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield Reseal > Page 12136 8. CAUTION: Do not drive the vehicle after installing windshield glass until the urethane adhesive has cured. Inadequate curing of the urethane adhesive adversely affects the strength of the urethane adhesive bond. Apply a bead of Urethane Adhesive to the pinch weld just outside the foam butyl dam over the top of the existing urethane bed. 9. CAUTION: Open the windows to prevent the windshield glass from being pushed out by air pressure if a door is closed. Using the alignment marks, install the windshield glass. 10. Install the windshield side mouldings. NOTE: Be sure the moldings seat completely. 11. Install the headliner. 12. Install the interior rear view mirror. 13. Install the overhead console. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield Reseal > Page 12137 14. Install the A-pillar trim panels. - Install the bolts and covers. 15. Install the sun visors. 1 Position the sun visors. 2 Install the 4 screws. If equipped, connect the electrical connectors. 16. Install the cowl grille. 17. Run the blower motor on defrost HIGH to check for glass that may have fallen into the defroster vents. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 12143 C138 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations View 151-14 (Steering Column) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 12147 Windshield Washer Switch: Diagrams C202a C202b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 12148 C202c Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 12149 Windshield Washer Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 12150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 12151 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Blade Heater Switch > Component Information > Locations View 151-33 (Climate Control System) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Blade Heater Switch > Component Information > Locations > Page 12155 C2323 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations View 151-14 (Steering Column) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 12159 Wiper Switch: Diagrams C202a C202b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 12160 C202c Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 12161 Wiper Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 12162 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 12163 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 12167 C138 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations View 151-1 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations > Page 12171 C1357 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair Windshield Washer Pump: Service and Repair WINDSHIELD WASHER PUMP AND RESERVOIR Removal and Installation 1. Disconnect the electrical connectors. 2. Remove the windshield washer reservoir screws. - To install, tighten to 5 Nm (44 lb-in). 3. NOTE: Windshield washer fluid should be collected in a container after the windshield washer hoses are disconnected. Disconnect the windshield washer hoses. 4. Remove the windshield washer reservoir. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Page 12175 5. Remove the windshield washer pump if necessary. 6. CAUTION: Do not operate the windshield washer pump prior to filling the windshield washer reservoir. To install, reverse the removal procedure. Fill the windshield washer reservoir with windshield washer concentrate. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair Windshield Washer Reservoir: Service and Repair WINDSHIELD WASHER PUMP AND RESERVOIR Removal and Installation 1. Disconnect the electrical connectors. 2. Remove the windshield washer reservoir screws. - To install, tighten to 5 Nm (44 lb-in). 3. NOTE: Windshield washer fluid should be collected in a container after the windshield washer hoses are disconnected. Disconnect the windshield washer hoses. 4. Remove the windshield washer reservoir. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Page 12179 5. Remove the windshield washer pump if necessary. 6. CAUTION: Do not operate the windshield washer pump prior to filling the windshield washer reservoir. To install, reverse the removal procedure. Fill the windshield washer reservoir with windshield washer concentrate. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations View 151-14 (Steering Column) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 12183 Windshield Washer Switch: Diagrams C202a C202b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 12184 C202c Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 12185 Windshield Washer Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 12186 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 12187 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments > Windshield Wiper Blade and Pivot Arm Adjustment Wiper Arm: Adjustments Windshield Wiper Blade and Pivot Arm Adjustment WINDSHIELD WIPER BLADE AND PIVOT ARM ADJUSTMENT 1. Cycle and park the windshield wipers. 2. Verify the distance between the outer tip of the (1) RH windshield wiper blade and the (3) bottom of the windshield glass and between the outer tip of the (2) LH windshield wiper blade and the (3) bottom of the windshield glass are within specifications. 3. If the distance is not within specification, remove the windshield wiper pivot arm and reposition to specification. 1 Lift the pivot arm nut cover. 2 Remove the nut. 4. Tighten the windshield wiper pivot arm nuts to 40 Nm (30 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments > Windshield Wiper Blade and Pivot Arm Adjustment > Page 12192 Wiper Arm: Adjustments Rear Window Wiper Blade and Pivot Arm Adjustment REAR WINDOW WIPER BLADE AND PIVOT ARM ADJUSTMENT 1. Cycle and park the rear window wiper pivot arm and blade. 2. Check the rear window wiper park measurement. If not within specification, the rear window wiper pivot arm will need to be removed. 3. CAUTION: Use a shop towel or similar device to protect the vehicle finish when carrying out the procedure. Remove the rear window wiper pivot arm. 1 Lift the pivot arm nut cover. 2 Remove the nut. 4. NOTE: This step makes sure that the wiper motor is in the PARK position. Turn the rear window wiper switch ON and allow the motor to operate for at least one cycle. Turn the rear window wiper switch to OFF. 5. Install the rear window wiper pivot arm onto the rear window wiper motor shaft. 1 Position the wiper pivot arm within specification. 2 Tighten the nut to 15 Nm (11 lb-ft). 3 Install the cover. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Pivot Arm - Windshield Wiper Wiper Arm: Service and Repair Wiper Pivot Arm - Windshield Wiper WIPER PIVOT ARM - WINDSHIELD WIPER Removal and Installation 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 Lift the pivot arm nut cover. 2 Remove the nut. - To install, tighten to 40 Nm (30 lb-ft). 5. To install, reverse the removal procedure. - Adjust the windshield wiper pivot arms. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Pivot Arm - Windshield Wiper > Page 12195 Wiper Arm: Service and Repair Wiper Pivot Arm - Rear WIPER PIVOT ARM - REAR Removal 1. CAUTION: Use a shop towel or similar device to protect the vehicle finish when carrying out the procedure. Remove the rear window wiper pivot arm. 1 Lift the pivot arm nut cover. 2 Remove the nut. Installation 1. NOTE: This step makes sure that the wiper motor is in the PARK position. Turn the rear window wiper switch ON and allow the motor to operate for at least one cycle. Turn the rear window wiper switch to OFF. 2. Install the rear window wiper pivot arm onto the rear window wiper motor shaft. 1 Position the wiper pivot arm within specification. 2 Tighten the nut to 15 Nm (11 lb-ft). 3 Install the cover. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Pivot Arm - Windshield Wiper > Page 12196 Wiper Arm: Service and Repair Wiper and Washer System - Exploded View WIPER AND WASHER SYSTEM - EXPLODED VIEW Wiper And Washer System - Front Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Pivot Arm - Windshield Wiper > Page 12197 Wiper And Washer System - Rear Removal And Installation 1. For additional information, refer to the procedures. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Adjustments > Windshield Wiper Blade and Pivot Arm Adjustment Wiper Blade: Adjustments Windshield Wiper Blade and Pivot Arm Adjustment WINDSHIELD WIPER BLADE AND PIVOT ARM ADJUSTMENT 1. Cycle and park the windshield wipers. 2. Verify the distance between the outer tip of the (1) RH windshield wiper blade and the (3) bottom of the windshield glass and between the outer tip of the (2) LH windshield wiper blade and the (3) bottom of the windshield glass are within specifications. 3. If the distance is not within specification, remove the windshield wiper pivot arm and reposition to specification. 1 Lift the pivot arm nut cover. 2 Remove the nut. 4. Tighten the windshield wiper pivot arm nuts to 40 Nm (30 lb-ft). Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Adjustments > Windshield Wiper Blade and Pivot Arm Adjustment > Page 12202 Wiper Blade: Adjustments Rear Window Wiper Blade and Pivot Arm Adjustment REAR WINDOW WIPER BLADE AND PIVOT ARM ADJUSTMENT 1. Cycle and park the rear window wiper pivot arm and blade. 2. Check the rear window wiper park measurement. If not within specification, the rear window wiper pivot arm will need to be removed. 3. CAUTION: Use a shop towel or similar device to protect the vehicle finish when carrying out the procedure. Remove the rear window wiper pivot arm. 1 Lift the pivot arm nut cover. 2 Remove the nut. 4. NOTE: This step makes sure that the wiper motor is in the PARK position. Turn the rear window wiper switch ON and allow the motor to operate for at least one cycle. Turn the rear window wiper switch to OFF. 5. Install the rear window wiper pivot arm onto the rear window wiper motor shaft. 1 Position the wiper pivot arm within specification. 2 Tighten the nut to 15 Nm (11 lb-ft). 3 Install the cover. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Blade Heater Switch > Component Information > Locations View 151-33 (Climate Control System) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Blade Heater Switch > Component Information > Locations > Page 12206 C2323 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement Technical Service Bulletin # 05S40S2 Date: 061019 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12215 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12216 Attachment I - Administrative Information OASIS ACTIVATED? Yes. OASIS was activated by November 9, 2005 FSA VIN LIST ACTIVATED? Yes Available through the website as of November 11, 2005. Owner names and addresses were made available November 28, 2005. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter (when available) and schedule a service date ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE Related damage claims are not approved for this program. ADDITIONAL LABOR TIME This repair will require no additional labor time to complete. Claims submitted with "MT" labor will not be accepted for reimbursement. OWNER REFUNDS Refunds are not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ For Labor Operation 05S40C, claim grease as miscellaneous expense code "OTHER" - for the amount of $0.10 per vehicle. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12217 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12218 LABOR ALLOWANCES (REMINDER: Only one labor operation will be accepted for each VIN.) [NEW!] PARTS REQUIREMENTS / ORDERING INFORMATION DEALER PRICE For latest prices, refer to DOES II. [NEW!] PARTS RETENTION AND RETURN Affected Wiper Motors that were replaced are subject to random return to the Ford Warranty Parts Analysis Center (WPAC) for supplier analysis. Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12219 Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. DEALER SORT/INSPECTION OF PARTS INVENTORY Dealers must inspect all wiper motor inventories with part numbers shown below. Wiper motors with a package label date of 8/26/05 through 10/21/05 should be returned to Ford. Those with an earlier or later packaging date are okay for use. For those found within the suspect date range, file a DOES II defective parts claim and include the information shown below. ^ Shipper Number: FSA 05S40 ^ Comments: Wiper Motor Return ^ Return Reason Code: CD Attachment III - Technical Information OVERVIEW This program involves inspecting the wiper motor manufacture code, then it necessary, inspecting for the presence of grease under the gear cover. Based on your inspection, ^ the vehicle may be reassembled and released, or ^ the wiper motor assembly will be replaced, or ^ [NEW] grease will be applied to the metal worm and plastic ring gears. INSPECTION The manufacture code is laser etched onto the cylindrical wiper motor housing. The code consists of two (2) lines of numbers. One line shows the wiper motor assembly engineering part number. The other line shows the date and time of manufacture, the assembly line it was built on (N for north or S for south) then the voltage of the motor. The wiper motor assemblies that require additional inspection for the presence of grease on the gears were built from 8-26-05 through 10-10-05 on the south assembly line. Any motor built before or after these dates, or built on the north assembly line, requires no additional inspection and the vehicle can be immediately released. See Figure 1. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12220 In some instances, the laser etching will be difficult to read. For these instances, the wiper motor gear cover must be removed to inspect for the presence of grease on the gear assemblies. The amount of grease will vary from motor to motor. If ANY grease is present on the worm or ring gear teeth, that wiper motor assembly requires no further service and the vehicle can be reassembled. In most cases, the etching can be viewed with minimal removal of parts. Generally, the left wiper arm and left cowl panel grille have to be removed to view the motor and manufacture code. Refer to the appropriate disassembly procedure for the vehicle being inspected. Then after accessing the manufacture code, refer to Inspection Results in this Attachment III. ESCAPE, MARINER, ESCAPE HYBRID, MARINER HYBRID NOTE: All Escape, Mariner, Escape Hybrid and Mariner Hybrid vehicles have wiper motor assemblies that were built on the south assembly line. Therefore, it is only necessary to inspect the manufacture date code. 1. Remove the left cowl panel grille plastic pin-type retainers from along the front of the panel. 2. Carefully lift the left cowl panel to enable viewing of the wiper motor assembly and note the manufacture DATE code on the motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label. 3. Proceed to Inspection Results in this Attachment III. E-SERIES 1. Remove the left wiper arm by lifting the arm slightly and releasing the lock tab, then removing the arm off of the shaft. 2. Remove the left cowl grille panel retainer screws, then remove the panel. 3. Note the manufacture code on the wiper motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label. 4. Proceed to Inspection Results in this Attachment III. EXPEDITION, NAVIGATOR 1. Park the wipers in the highest position on the glass. 2. Lift the wiper arm nut cover. Remove the retaining nut and lift the arm off of the shaft. 3. Position aside the cowl grille panel seal. 4. Remove the pin-type retainer from the far left end of the panel, then lift the panel, disconnect the washer hose and remove the panel from the Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12221 vehicle. 5. Note the manufacture code on the wiper motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label. 6. Proceed to Inspection Results in this Attachment III. EXPLORER, MOUNTAINEER 1. Remove both wiper arms by lifting the arms slightly and releasing the lock tabs, then remove the arms off of the shafts. 2. Remove the passenger side, then the driver side cowl grille panels. 3. Note the manufacture code on the wiper motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label. 4. Proceed to Inspection Results in this Attachment III. F-150, MARK LT 1. Remove the wiper arms by releasing the lock tabs and lifting the arms off of the shafts. 2. Remove the cowl grille panel plastic pin-type retainers (one per panel located near the fenders). 3. CAUTION: To avoid breaking the retainer hooks on the cowl grille panel, do not pull on the rear of the panel. A) Remove the left (driver side) cowl grille panel, then the right (passenger side) panel. B) Release the FRONT EDGE of the panel as follows: ^ Starting at the center of the vehicle, depress the forward tab and press upward on the forward edge of the panel to release it from the cowl. ^ Continuing outward from the center of the vehicle, depress the remaining forward tabs and release the rest of the panel from the cowl. C) Release the REAR EDGE of the panel as follows: ^ Starting at the left fender, press down on the rear edge of the panel to release the retaining hook, then lightly pull the front edge of the panel forward. ^ Continuing toward the center of the vehicle, release the remaining hooks by pressing the panel down while gently pulling the panel forward. D) Disconnect the windshield washer hose and remove the cowl grille panel from the vehicle. 4. Note the manufacture code on the wiper motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label. 5. Proceed to Inspection Results in this Attachment III. RANGER 1. Open the hood and locate the wiper motor. 2. Note the manufacture code on the wiper motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label. 3. Proceed to Inspection Results in this Attachment III. TAURUS 1. Park the wipers in the highest position on the glass. 2. Remove the wiper arm nut covers. 3. Remove the nuts then pull the wiper arms up off of the shafts. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12222 4. Remove the cowl grille panel clips. 5. Remove the passenger side cowl grille panel, then the driver side panel. 6. Note the manufacture code on the wiper motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label. 7. Proceed to Inspection Results in this Attachment III. INSPECTION RESULTS 1. If the manufacture code cannot be read (even after removing the label), refer to Gear Cover Removal and Inspection in this Attachment III. 2. The wiper motor assembly does not require additional inspection if it was built: a) anytime on the north assembly line, or b) before 8-26-05 or after 10-10-05 on the south assembly line. Reassemble and release the vehicle. 3. The wiper motor assembly should be inspected further only if it was built: a) from 8-26-05 through 10-10-05 on the south assembly line. Refer to Gear Cover Removal and Inspection in this Attachment III. GEAR COVER REMOVAL AND INSPECTION 1. CAUTION: Use extreme care when bending the locking tabs back to remove the gear cover from the wiper motor. The cover is constructed with a glass reinforced resin which makes the tabs less flexible. Bend the tabs only far enough to release them from the lugs. Bending the tabs an excessive amount could cause them to break. Using a small pocket screwdriver placed under the lock tab, rotate the screwdriver to disengage the tab from the lug on the motor housing. Disengage all five (5) tabs in the order indicated in Figure 2. 2. CAUTION: On Taurus, Escape Mariner, Escape Hybrid, Mariner Hybrid and Ranger vehicles, the gear cover perimeter is sealed with silicone. Pry up around the perimeter of the gear cover to break the sealant from the cover. CAUTION: The gear cover must be squarely lifted oft of the motor housing. Any rocking or sideways motion may bend the three (3) internal electrical connector clips. Squarely lift the gear cover off of the motor housing. Discard the covers only on Taurus, Escape, Mariner, Escape Hybrid, Mariner Hybrid and Ranger vehicles. Retain the cover for reinstallation on all other affected models. If in the rare event a tab breaks off on of these covers, are a placement cover, part number 2L2Z-17C476-A, must be ordered.* [NEW]* Only order a new cover if grease is found and wiper motor assembly replacement is NOT required. (See Step 3) [NEW] 3. NOTE: QFP Grease can no longer be ordered. Dealers are to use their supply of grease on wiper motors which require it. Once the supply Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12223 of grease is exhausted, wiper motors are to be replaced when no grease is found during wiper motor inspection. Inspect the worm and ring gears for presence of grease. Any amount of grease is acceptable as long as there is some grease present on the worm and ring gears. See Figure 3. ^ If grease is present, no further service is required. Refer to Gear Cover Installation for specific cover installation procedures. ^ If no grease is present, apply a bead of grease, part number QFP, approximately 2-3 mm (1/8 in) wide and 20 mm (3/4 in) long, to the worm and ring gear mating area, beginning where the worm gear exits the motor. See Figure 3. The first tube will be shipped to dealers free of charge. DO NOT USE ANY OTHER GREASE. Then, refer to Gear Cover Installation for detailed gear cover installation procedures. ^ Refer to Attachment V for OFP Grease MSDS. ^ If grease is unavailable, replace the wiper motor assembly following the procedures in Section 501-16 of the appropriate workshop manual. GEAR COVER INSTALLATION NOTE: A new gear cover, part number 1F2Z-17D532-CA, must be installed on Taurus, Escape, Mariner, Escape Hybrid, Mariner Hybrid and Ranger vehicles. On all others, reinstall the original cover unless the locking tabs have been broken, bent or otherwise damaged, in which case, a new cover, part number 2L2Z-17C476-A, must be installed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12224 1. Inspect the three (3) internal electrical connector clips. All three (3) clips MUST be aligned against the plastic terminal holder. If any of the clips are misaligned or touching the motor housing, they must be straightened and positioned as shown in the illustration. See Figure 4. 2. NOTE: This step applies only to Taurus, Escape, Mariner, Escape Hybrid, Mariner Hybrid and Ranger vehicles. For all others, proceed to Step 3. CAUTION: Do not use solvents or compressed air to remove the sealant from the motor gear housing. Any solvent entering the gear cavity may damage the motor. Also, remove all large pieces of sealant that enter the gear housing cavity during cleaning. Small particles of sealant left in the cavity are acceptable. NOTE: It is not necessary to remove the existing sealant attached to the vertical surfaces inside the gear housing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12225 Remove the existing sealant from the top surface of the gear housing and around each of the five (5) mounting lug areas. To avoid damaging the motor, extra care must be taken when removing sealant from the area around the internal electrical connector clips. See Figure 5. 3. Verity that the three (3) electrical spade terminals are not bent. It necessary, straighten them so that they are perpendicular to the cover as illustrated in Figure 6. 4. Make sure that the foam gasket is properly seated in the new cover as shown in Figure 6. 5. NOTE: This step applies only to Taurus, Escape, Mariner, Escape Hybrid, Mariner Hybrid and Ranger vehicles. For all others, proceed to Step 6. Make sure that the white cam follower arm is positioned as shown in Figure 6. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12226 6. IMPORTANT: Position the cover on the gear housing so that each plastic locking tab is outside of the gear housing cavity and is resting over the mounting lugs. Ensure that the electrical spade terminals are lined up with the connector clips. See Figure 7. 7. Using two (2) hands, push the gear cover downward onto the gear housing uniformly, to ensure that the electrical terminals remain in alignment. Push down firmly until all five (5) locking tabs are latched correctly. See Figure 8. 8. CAUTION: If any of the locking tabs cannot be correctly latched as shown in Figure 9, contact the Special Service Support Center for further instructions. DO NOT attempt to remove the cover and reinstall it. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12227 9. Reassemble the vehicle following the disassembly procedures in reverse order. On Taurus and Expedition/Navigator vehicles, tighten the wiper arm attaching nuts to 40 Nm (30 lb-ft). 10. IMPORTANT: Check for proper wiper motor operation in all speeds, intermittent and wash, then release the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12228 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12229 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12230 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12231 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12232 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12233 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12234 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > NHTSA05V520000 > Nov > 05 > Recall 05V520000: Wiper Motor Inspection/Repair Wiper Motor: Recalls Recall 05V520000: Wiper Motor Inspection/Repair MAKE/MODELS: MODEL/BUILD YEARS: Ford/E-150 2006 Ford/E-250 2006 Ford/E-350 2006 Ford/E-450 2006 Ford/Escape 2006 Ford/Expedition 2006 Ford/Explorer 2006 Ford/F-150 2006 Ford/Ranger 2006 Ford/Taurus 2006 Lincoln/Mark LT 2006 Lincoln/Navigator 2006 Mercury/Mariner 2006 Mercury/Mountaineer 2006 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V520000 MFG'S REPORT DATE: November 07, 2005 COMPONENT: Visibility: Windshield Wiper/Washer: Motor POTENTIAL NUMBER OF UNITS AFFECTED: 199942 SUMMARY: On certain trucks, passenger cars and sport utility vehicles, the windshield wiper motor may have been produced without grease being applied to the output shaft gear. CONSEQUENCE: After a period of continuous use on the high speed setting, lack of grease on the output shaft gear may cause the gear to distort or fracture during operation resulting in a loss of wiper function. Inoperative wipers under inclement weather conditions could cause a crash due to impaired visibility. REMEDY: Dealers will inspect the wiper motor for the presence of grease and grease the wiper motor gears if necessary. The recall began on November 22, 2005. Owners should contact FORD at 1-800-392-3673 or Lincoln/Mercury at 1-800-521-4140. NOTES: Ford recall No. 05S40. 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement Technical Service Bulletin # 05S40S2 Date: 061019 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12244 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12245 Attachment I - Administrative Information OASIS ACTIVATED? Yes. OASIS was activated by November 9, 2005 FSA VIN LIST ACTIVATED? Yes Available through the website as of November 11, 2005. Owner names and addresses were made available November 28, 2005. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter (when available) and schedule a service date ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE Related damage claims are not approved for this program. ADDITIONAL LABOR TIME This repair will require no additional labor time to complete. Claims submitted with "MT" labor will not be accepted for reimbursement. OWNER REFUNDS Refunds are not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ For Labor Operation 05S40C, claim grease as miscellaneous expense code "OTHER" - for the amount of $0.10 per vehicle. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12246 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12247 LABOR ALLOWANCES (REMINDER: Only one labor operation will be accepted for each VIN.) [NEW!] PARTS REQUIREMENTS / ORDERING INFORMATION DEALER PRICE For latest prices, refer to DOES II. [NEW!] PARTS RETENTION AND RETURN Affected Wiper Motors that were replaced are subject to random return to the Ford Warranty Parts Analysis Center (WPAC) for supplier analysis. Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12248 Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. DEALER SORT/INSPECTION OF PARTS INVENTORY Dealers must inspect all wiper motor inventories with part numbers shown below. Wiper motors with a package label date of 8/26/05 through 10/21/05 should be returned to Ford. Those with an earlier or later packaging date are okay for use. For those found within the suspect date range, file a DOES II defective parts claim and include the information shown below. ^ Shipper Number: FSA 05S40 ^ Comments: Wiper Motor Return ^ Return Reason Code: CD Attachment III - Technical Information OVERVIEW This program involves inspecting the wiper motor manufacture code, then it necessary, inspecting for the presence of grease under the gear cover. Based on your inspection, ^ the vehicle may be reassembled and released, or ^ the wiper motor assembly will be replaced, or ^ [NEW] grease will be applied to the metal worm and plastic ring gears. INSPECTION The manufacture code is laser etched onto the cylindrical wiper motor housing. The code consists of two (2) lines of numbers. One line shows the wiper motor assembly engineering part number. The other line shows the date and time of manufacture, the assembly line it was built on (N for north or S for south) then the voltage of the motor. The wiper motor assemblies that require additional inspection for the presence of grease on the gears were built from 8-26-05 through 10-10-05 on the south assembly line. Any motor built before or after these dates, or built on the north assembly line, requires no additional inspection and the vehicle can be immediately released. See Figure 1. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12249 In some instances, the laser etching will be difficult to read. For these instances, the wiper motor gear cover must be removed to inspect for the presence of grease on the gear assemblies. The amount of grease will vary from motor to motor. If ANY grease is present on the worm or ring gear teeth, that wiper motor assembly requires no further service and the vehicle can be reassembled. In most cases, the etching can be viewed with minimal removal of parts. Generally, the left wiper arm and left cowl panel grille have to be removed to view the motor and manufacture code. Refer to the appropriate disassembly procedure for the vehicle being inspected. Then after accessing the manufacture code, refer to Inspection Results in this Attachment III. ESCAPE, MARINER, ESCAPE HYBRID, MARINER HYBRID NOTE: All Escape, Mariner, Escape Hybrid and Mariner Hybrid vehicles have wiper motor assemblies that were built on the south assembly line. Therefore, it is only necessary to inspect the manufacture date code. 1. Remove the left cowl panel grille plastic pin-type retainers from along the front of the panel. 2. Carefully lift the left cowl panel to enable viewing of the wiper motor assembly and note the manufacture DATE code on the motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label. 3. Proceed to Inspection Results in this Attachment III. E-SERIES 1. Remove the left wiper arm by lifting the arm slightly and releasing the lock tab, then removing the arm off of the shaft. 2. Remove the left cowl grille panel retainer screws, then remove the panel. 3. Note the manufacture code on the wiper motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label. 4. Proceed to Inspection Results in this Attachment III. EXPEDITION, NAVIGATOR 1. Park the wipers in the highest position on the glass. 2. Lift the wiper arm nut cover. Remove the retaining nut and lift the arm off of the shaft. 3. Position aside the cowl grille panel seal. 4. Remove the pin-type retainer from the far left end of the panel, then lift the panel, disconnect the washer hose and remove the panel from the Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12250 vehicle. 5. Note the manufacture code on the wiper motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label. 6. Proceed to Inspection Results in this Attachment III. EXPLORER, MOUNTAINEER 1. Remove both wiper arms by lifting the arms slightly and releasing the lock tabs, then remove the arms off of the shafts. 2. Remove the passenger side, then the driver side cowl grille panels. 3. Note the manufacture code on the wiper motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label. 4. Proceed to Inspection Results in this Attachment III. F-150, MARK LT 1. Remove the wiper arms by releasing the lock tabs and lifting the arms off of the shafts. 2. Remove the cowl grille panel plastic pin-type retainers (one per panel located near the fenders). 3. CAUTION: To avoid breaking the retainer hooks on the cowl grille panel, do not pull on the rear of the panel. A) Remove the left (driver side) cowl grille panel, then the right (passenger side) panel. B) Release the FRONT EDGE of the panel as follows: ^ Starting at the center of the vehicle, depress the forward tab and press upward on the forward edge of the panel to release it from the cowl. ^ Continuing outward from the center of the vehicle, depress the remaining forward tabs and release the rest of the panel from the cowl. C) Release the REAR EDGE of the panel as follows: ^ Starting at the left fender, press down on the rear edge of the panel to release the retaining hook, then lightly pull the front edge of the panel forward. ^ Continuing toward the center of the vehicle, release the remaining hooks by pressing the panel down while gently pulling the panel forward. D) Disconnect the windshield washer hose and remove the cowl grille panel from the vehicle. 4. Note the manufacture code on the wiper motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label. 5. Proceed to Inspection Results in this Attachment III. RANGER 1. Open the hood and locate the wiper motor. 2. Note the manufacture code on the wiper motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label. 3. Proceed to Inspection Results in this Attachment III. TAURUS 1. Park the wipers in the highest position on the glass. 2. Remove the wiper arm nut covers. 3. Remove the nuts then pull the wiper arms up off of the shafts. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12251 4. Remove the cowl grille panel clips. 5. Remove the passenger side cowl grille panel, then the driver side panel. 6. Note the manufacture code on the wiper motor. If the code cannot be seen AND there is a small label affixed to the wiper motor cylindrical housing, remove and discard the label. The code may be under the label. 7. Proceed to Inspection Results in this Attachment III. INSPECTION RESULTS 1. If the manufacture code cannot be read (even after removing the label), refer to Gear Cover Removal and Inspection in this Attachment III. 2. The wiper motor assembly does not require additional inspection if it was built: a) anytime on the north assembly line, or b) before 8-26-05 or after 10-10-05 on the south assembly line. Reassemble and release the vehicle. 3. The wiper motor assembly should be inspected further only if it was built: a) from 8-26-05 through 10-10-05 on the south assembly line. Refer to Gear Cover Removal and Inspection in this Attachment III. GEAR COVER REMOVAL AND INSPECTION 1. CAUTION: Use extreme care when bending the locking tabs back to remove the gear cover from the wiper motor. The cover is constructed with a glass reinforced resin which makes the tabs less flexible. Bend the tabs only far enough to release them from the lugs. Bending the tabs an excessive amount could cause them to break. Using a small pocket screwdriver placed under the lock tab, rotate the screwdriver to disengage the tab from the lug on the motor housing. Disengage all five (5) tabs in the order indicated in Figure 2. 2. CAUTION: On Taurus, Escape Mariner, Escape Hybrid, Mariner Hybrid and Ranger vehicles, the gear cover perimeter is sealed with silicone. Pry up around the perimeter of the gear cover to break the sealant from the cover. CAUTION: The gear cover must be squarely lifted oft of the motor housing. Any rocking or sideways motion may bend the three (3) internal electrical connector clips. Squarely lift the gear cover off of the motor housing. Discard the covers only on Taurus, Escape, Mariner, Escape Hybrid, Mariner Hybrid and Ranger vehicles. Retain the cover for reinstallation on all other affected models. If in the rare event a tab breaks off on of these covers, are a placement cover, part number 2L2Z-17C476-A, must be ordered.* [NEW]* Only order a new cover if grease is found and wiper motor assembly replacement is NOT required. (See Step 3) [NEW] 3. NOTE: QFP Grease can no longer be ordered. Dealers are to use their supply of grease on wiper motors which require it. Once the supply Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12252 of grease is exhausted, wiper motors are to be replaced when no grease is found during wiper motor inspection. Inspect the worm and ring gears for presence of grease. Any amount of grease is acceptable as long as there is some grease present on the worm and ring gears. See Figure 3. ^ If grease is present, no further service is required. Refer to Gear Cover Installation for specific cover installation procedures. ^ If no grease is present, apply a bead of grease, part number QFP, approximately 2-3 mm (1/8 in) wide and 20 mm (3/4 in) long, to the worm and ring gear mating area, beginning where the worm gear exits the motor. See Figure 3. The first tube will be shipped to dealers free of charge. DO NOT USE ANY OTHER GREASE. Then, refer to Gear Cover Installation for detailed gear cover installation procedures. ^ Refer to Attachment V for OFP Grease MSDS. ^ If grease is unavailable, replace the wiper motor assembly following the procedures in Section 501-16 of the appropriate workshop manual. GEAR COVER INSTALLATION NOTE: A new gear cover, part number 1F2Z-17D532-CA, must be installed on Taurus, Escape, Mariner, Escape Hybrid, Mariner Hybrid and Ranger vehicles. On all others, reinstall the original cover unless the locking tabs have been broken, bent or otherwise damaged, in which case, a new cover, part number 2L2Z-17C476-A, must be installed. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12253 1. Inspect the three (3) internal electrical connector clips. All three (3) clips MUST be aligned against the plastic terminal holder. If any of the clips are misaligned or touching the motor housing, they must be straightened and positioned as shown in the illustration. See Figure 4. 2. NOTE: This step applies only to Taurus, Escape, Mariner, Escape Hybrid, Mariner Hybrid and Ranger vehicles. For all others, proceed to Step 3. CAUTION: Do not use solvents or compressed air to remove the sealant from the motor gear housing. Any solvent entering the gear cavity may damage the motor. Also, remove all large pieces of sealant that enter the gear housing cavity during cleaning. Small particles of sealant left in the cavity are acceptable. NOTE: It is not necessary to remove the existing sealant attached to the vertical surfaces inside the gear housing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12254 Remove the existing sealant from the top surface of the gear housing and around each of the five (5) mounting lug areas. To avoid damaging the motor, extra care must be taken when removing sealant from the area around the internal electrical connector clips. See Figure 5. 3. Verity that the three (3) electrical spade terminals are not bent. It necessary, straighten them so that they are perpendicular to the cover as illustrated in Figure 6. 4. Make sure that the foam gasket is properly seated in the new cover as shown in Figure 6. 5. NOTE: This step applies only to Taurus, Escape, Mariner, Escape Hybrid, Mariner Hybrid and Ranger vehicles. For all others, proceed to Step 6. Make sure that the white cam follower arm is positioned as shown in Figure 6. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12255 6. IMPORTANT: Position the cover on the gear housing so that each plastic locking tab is outside of the gear housing cavity and is resting over the mounting lugs. Ensure that the electrical spade terminals are lined up with the connector clips. See Figure 7. 7. Using two (2) hands, push the gear cover downward onto the gear housing uniformly, to ensure that the electrical terminals remain in alignment. Push down firmly until all five (5) locking tabs are latched correctly. See Figure 8. 8. CAUTION: If any of the locking tabs cannot be correctly latched as shown in Figure 9, contact the Special Service Support Center for further instructions. DO NOT attempt to remove the cover and reinstall it. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12256 9. Reassemble the vehicle following the disassembly procedures in reverse order. On Taurus and Expedition/Navigator vehicles, tighten the wiper arm attaching nuts to 40 Nm (30 lb-ft). 10. IMPORTANT: Check for proper wiper motor operation in all speeds, intermittent and wash, then release the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12257 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12258 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12259 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12260 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12261 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12262 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 05S40S2 > Oct > 06 > Recall - Wiper Motor Inspection/Replacement > Page 12263 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > NHTSA05V520000 > Nov > 05 > Recall 05V520000: Wiper Motor Inspection/Repair Wiper Motor: All Technical Service Bulletins Recall 05V520000: Wiper Motor Inspection/Repair MAKE/MODELS: MODEL/BUILD YEARS: Ford/E-150 2006 Ford/E-250 2006 Ford/E-350 2006 Ford/E-450 2006 Ford/Escape 2006 Ford/Expedition 2006 Ford/Explorer 2006 Ford/F-150 2006 Ford/Ranger 2006 Ford/Taurus 2006 Lincoln/Mark LT 2006 Lincoln/Navigator 2006 Mercury/Mariner 2006 Mercury/Mountaineer 2006 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V520000 MFG'S REPORT DATE: November 07, 2005 COMPONENT: Visibility: Windshield Wiper/Washer: Motor POTENTIAL NUMBER OF UNITS AFFECTED: 199942 SUMMARY: On certain trucks, passenger cars and sport utility vehicles, the windshield wiper motor may have been produced without grease being applied to the output shaft gear. CONSEQUENCE: After a period of continuous use on the high speed setting, lack of grease on the output shaft gear may cause the gear to distort or fracture during operation resulting in a loss of wiper function. Inoperative wipers under inclement weather conditions could cause a crash due to impaired visibility. REMEDY: Dealers will inspect the wiper motor for the presence of grease and grease the wiper motor gears if necessary. The recall began on November 22, 2005. Owners should contact FORD at 1-800-392-3673 or Lincoln/Mercury at 1-800-521-4140. NOTES: Ford recall No. 05S40. 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Windshield Wiper Motor View 151-2 (Engine Compartment) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Windshield Wiper Motor > Page 12270 View 151-32 (Liftgate) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions Wiper Motor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (as if the ignition switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A referance is given to the page where the splice appears in full. It is also listed in the index. Component Referencing (4) Each Component on a diagram has a reference to the component location view or the diagram where it is shown completely. It is located to the right of each component. Component Names,Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears in the publication. Internal Name and Function Identification Numbers (6) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 12273 Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Circuit Function Identifiers (7) Some components without internal diagrams use symbols or text to describe the function of a circuit in a system. Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse-/relay box, in which all fuses and relays are identified. Fuse and Relay Numbering and Naming Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. "F 1." precedes Battery Junction Box fuses, and "F2." precedes Central Junction Box fuses. Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 12274 Ground Distribution Power and Ground Distribution Diagrams contains the diagram that shows the complete details for each ground connection or main ground splice. There is also a description of the ground location of the vehicle and the harness it resides on. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual set diagrams as uncluttered as possible. C150 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 12275 C1033 Component and Connector Information Location information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given, along with a reference to the component location views. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing lose clothing. Symbols Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 12276 Symbols Part 1 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 12277 Symbols Part 2 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 12278 Symbols Part 3 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 12279 Symbols Part 4 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 12280 Symbols Part 5 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 12281 Symbols Part 6 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 12282 Wiper Motor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 12283 Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 12284 Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 12285 Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring Strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16AWG and Smaller Diameter Wire Only) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 12286 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 12287 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 12288 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R59O1 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R59O1 Pro-Crimper is the only tool that can be used with these splices. 6. Center one end of the wire splice in the appropriate crimping chamber. 7. Insert stripped wire into the barrel. 8. Holding the wire in place, squeeze tool handles until ratchet releases. 9. Repeating steps 5-7, crimp the other half of the splice. 10. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 12289 11. Evenly position supplied heat shrink tubing over wire repair. 12. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 13. Reconnect battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 12290 Wiper Motor: Connector Views C125 C476 Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Windshield Wiper Motor Wiper Motor: Testing and Inspection Windshield Wiper Motor WINDSHIELD WIPER MOTOR CAUTION: Do not handle the windshield wiper motor abusively when diagnosing the wiper operations. Failure to follow this caution may result in damage to the motor magnets and will make the windshield wiper motor inoperative. Rough handling of new windshield wiper motors may also damage the motor magnets. NOTE: - Windshield wiper motor component test is carried out to determine if windshield wiper motor and module are functional and not in default mode. Refer to Principles of Operation. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Principles of Operation - Battery voltage must remain within 10 to 15 VDC to carry out test and keep windshield wiper motor from entering its software safe mode. - When connecting the power and ground test leads to the windshield wiper motor terminals, care must be taken to not short terminals between power and ground, as well as making sure the logic ground, pin 3, is always securely connected to prevent permanent windshield wiper motor module damage. If the windshield wiper motor does not pass any of the following tests, install a new windshield wiper motor. Use SABRE Premium Battery and Electrical System Tester 010-00736 or equivalent to test the windshield wiper motor. To test the windshield wiper motor, remove the windshield wiper mounting arm and pivot shaft from the windshield wiper motor. Disconnect the wiper motor. Connect the (1) green lead from the (2) SABRE to the battery negative (-) post. Connect the red lead (3) from the SABRE to the wiper motor (4) component side connector ground and logic ground pins 6 and 3 (3). Connect battery positive cable (5) to windshield wiper motor (4) component side connector battery and logic positive pins 5 and 8 (5). Low Speed Test the LOW SPEED mode by connecting a separate set of test leads from battery ground (-) post to windshield wiper motor (4) component side pins 9 and 10 (6). When these pins are grounded, the windshield wiper motor operation should now be in low speed mode. High Speed Test the HIGH SPEED mode by connecting a separate set of test leads from battery ground (-) post to windshield wiper motor (4) component side pins 1, 9 and 10 (7). When these pins are grounded, the windshield wiper motor operation should now be in high speed mode. Washer Pump Relay (Integral) Test the windshield wiper motor internal washer relay function by measuring the voltage between windshield wiper motor (4) component side pin 7 (8) and ground while grounding the windshield wiper motor (4) component side pin 12 (9). When wash command input pin 12 is grounded, measured voltage should read 10 volts or greater. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Windshield Wiper Motor > Page 12293 Wiper Motor: Testing and Inspection Rear Window Wiper Motor REAR WINDOW WIPER MOTOR CAUTION: Do not handle the rear window wiper motor abusively when diagnosing the wiper operations. Failure to follow this caution may result in damage to the motor magnets and will make the rear window wiper motor inoperative. Rough handling of new rear window wiper motors may also damage the motor magnets. NOTE: - The rear window wiper motor component test is carried out to determine if wiper motor and module are functional. - Battery voltage must remain within 10 to 15 VDC to carry out test and keep wiper motor from entering its software safe mode. - When connecting the power and ground test leads to the rear wiper motor terminals, care must be taken to not short terminals between power and ground, as well as making sure the logic ground, pin 3, is always securely connected to prevent permanent rear window wiper motor module damage. If the rear window wiper motor does not pass any of the following tests, install a new rear window wiper motor. Use the SABRE Premium Battery and Electrical System Tester 010-00736 or equivalent to test the rear window wiper motor. Disconnect the rear window wiper motor. Connect the (1) green lead from the (2) SABRE to the battery negative (-) post. Connect the red lead (3) from the SABRE to the wiper motor (4) component side connector ground pins 1 an 2 (3). Connect battery positive cable (5) to wiper motor (4) component side connector battery and logic positive pins 3 and 4 (5). On Mode Test the ON mode by connecting a separate set of test leads from battery ground (-) post to windshield wiper motor (4) component side pins 6 and 7 (6). When these pins are grounded, the rear window wiper motor operation should now be in ON mode. Washer Pump Relay (Integral) Test the rear window wiper motor internal washer relay function by measuring the voltage between wiper motor (4) component side pin 5 (7) and ground. When wash command input pin 6 (7) is grounded, measured voltage should read 10 volts or greater. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper and Washer System - Exploded View Wiper Motor: Service and Repair Wiper and Washer System - Exploded View WIPER AND WASHER SYSTEM - EXPLODED VIEW Wiper And Washer System - Front Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper and Washer System - Exploded View > Page 12296 Wiper And Washer System - Rear Removal And Installation 1. For additional information, refer to the procedures. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper and Washer System - Exploded View > Page 12297 Wiper Motor: Service and Repair Windshield Wiper Motor WINDSHIELD WIPER MOTOR Removal and Installation 1. Remove the mounting arm and pivot shaft. 2. NOTE: Mark the position of the windshield wiper motor crank before it is disconnected. Disconnect the windshield wiper motor crank. Remove the bolt. - To install, tighten to 18 Nm (13 lb-ft). 3. Remove the bolts and the windshield wiper motor. - To install, tighten to 15 Nm (11 ft-lb). 4. NOTE: The windshield wiper motor crank must be set to the same location for the windshield wiper mounting arm and pivot shaft to be installed properly. Refer to Component test. To install reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper and Washer System - Exploded View > Page 12298 Wiper Motor: Service and Repair Rear Window Wiper Motor REAR WINDOW WIPER MOTOR Removal 1. Remove the rear wiper pivot arm. 2. Remove the dust boot cover. 3. Remove the rear window wiper pivot shaft nut and handle. - To install, tighten to 18 Nm (13 lb-ft). 4. Open the liftgate glass. 5. Remove the nuts and the rear window striker and wiper pivot shaft assembly. - To install, tighten to 6 Nm (53 lb-in). 6. Remove the liftgate trim panel. 7. Close the liftgate. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper and Washer System - Exploded View > Page 12299 8. If installing a new rear wiper motor, remove the liftgate window glass latch. 1 Disconnect the electrical connector. 2 Remove the bolts. - To install, tighten to 8 Nm (71 lb-in). 9. Remove the rear window wiper motor. 1 Disconnect the electrical connector. 2 Remove the bolts. - To install, tighten to 11 Nm (8 lb-ft). Installation 1. If installing a new rear wiper motor, install the liftgate window glass latch. - Tighten bolts to 8 Nm (71 lb-in). 2. NOTE: An audible click should be heard as the striker engages the latch. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper and Washer System - Exploded View > Page 12300 Push the rear window wiper striker and pivot shaft assembly into the wiper motor. The pivot shaft pin should be aligned with the hole in the motor disc. 3. Install the rear window wiper motor alignment tool. If installing a new rear wiper motor, one is provided with the motor assembly. 1 Make sure the alignment tool fits over the motor disc and striker assembly. 2 Make sure the alignment tool clips are securely engaged. 4. Install the rear wiper motor. 1 Tighten the bolts to 11 Nm (8 lb-ft). 2 Connect the electrical connectors. 5. Carefully close the liftgate glass. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper and Washer System - Exploded View > Page 12301 6. Open the liftgate. Install the rear window wiper striker and wiper pivot arm mounting assembly nuts. - Tighten to 6 Nm (53 lb-in). 7. Close the liftgate. 8. Install the rear window wiper pivot shaft nut and handle. - Tighten to 18 Nm (13 lb-ft). 9. Install the dust boot cover. 10. Install the rear wiper pivot arm. 11. Open the liftgate. 12. Remove the rear window wiper motor aligning tool. 13. Open the liftgate glass. 14. Install the liftgate trim panel. 15. Test the liftgate and liftgate glass for normal operation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical Service Bulletins > Recalls: > NHTSA05V520000 > Nov > 05 > Recall 05V520000: Wiper Motor Inspection/Repair Wiper Motor Linkage: Recalls Recall 05V520000: Wiper Motor Inspection/Repair MAKE/MODELS: MODEL/BUILD YEARS: Ford/E-150 2006 Ford/E-250 2006 Ford/E-350 2006 Ford/E-450 2006 Ford/Escape 2006 Ford/Expedition 2006 Ford/Explorer 2006 Ford/F-150 2006 Ford/Ranger 2006 Ford/Taurus 2006 Lincoln/Mark LT 2006 Lincoln/Navigator 2006 Mercury/Mariner 2006 Mercury/Mountaineer 2006 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V520000 MFG'S REPORT DATE: November 07, 2005 COMPONENT: Visibility: Windshield Wiper/Washer: Motor POTENTIAL NUMBER OF UNITS AFFECTED: 199942 SUMMARY: On certain trucks, passenger cars and sport utility vehicles, the windshield wiper motor may have been produced without grease being applied to the output shaft gear. CONSEQUENCE: After a period of continuous use on the high speed setting, lack of grease on the output shaft gear may cause the gear to distort or fracture during operation resulting in a loss of wiper function. Inoperative wipers under inclement weather conditions could cause a crash due to impaired visibility. REMEDY: Dealers will inspect the wiper motor for the presence of grease and grease the wiper motor gears if necessary. The recall began on November 22, 2005. Owners should contact FORD at 1-800-392-3673 or Lincoln/Mercury at 1-800-521-4140. NOTES: Ford recall No. 05S40. 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > NHTSA05V520000 > Nov > 05 > Recall 05V520000: Wiper Motor Inspection/Repair Wiper Motor Linkage: All Technical Service Bulletins Recall 05V520000: Wiper Motor Inspection/Repair MAKE/MODELS: MODEL/BUILD YEARS: Ford/E-150 2006 Ford/E-250 2006 Ford/E-350 2006 Ford/E-450 2006 Ford/Escape 2006 Ford/Expedition 2006 Ford/Explorer 2006 Ford/F-150 2006 Ford/Ranger 2006 Ford/Taurus 2006 Lincoln/Mark LT 2006 Lincoln/Navigator 2006 Mercury/Mariner 2006 Mercury/Mountaineer 2006 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V520000 MFG'S REPORT DATE: November 07, 2005 COMPONENT: Visibility: Windshield Wiper/Washer: Motor POTENTIAL NUMBER OF UNITS AFFECTED: 199942 SUMMARY: On certain trucks, passenger cars and sport utility vehicles, the windshield wiper motor may have been produced without grease being applied to the output shaft gear. CONSEQUENCE: After a period of continuous use on the high speed setting, lack of grease on the output shaft gear may cause the gear to distort or fracture during operation resulting in a loss of wiper function. Inoperative wipers under inclement weather conditions could cause a crash due to impaired visibility. REMEDY: Dealers will inspect the wiper motor for the presence of grease and grease the wiper motor gears if necessary. The recall began on November 22, 2005. Owners should contact FORD at 1-800-392-3673 or Lincoln/Mercury at 1-800-521-4140. NOTES: Ford recall No. 05S40. 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 (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiper Motor Linkage: > 07-10-13 > May > 07 > Wipers/Washers - Rear Wiper is Inoperative Wiper Pivot: All Technical Service Bulletins Wipers/Washers - Rear Wiper is Inoperative TSB 07-10-13 05/28/07 REAR WIPER INOPERATIVE FORD: 2003-2007 Expedition LINCOLN: 2003-2007 Navigator This article supersedes TSB 06-22-10 to update the vehicle model years. ISSUE Some 2003-2007 Expedition and Navigator vehicles, the rear wiper may not return to park position. In this case, the rear wiper system will attempt to park periodically causing a battery drain.This concern may be caused by corrosion on the wiper pivot shaft assembly. ACTION Use the following Service Procedure to identify and replace the rear window striker/wiper pivot shaft assembly. SERVICE PROCEDURE 1. Disengage rear wiper mechanism by partially opening the rear liftgate glass. (Figure 1) 2. Access the rear wiper arm attaching nut. (Figure 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiper Motor Linkage: > 07-10-13 > May > 07 > Wipers/Washers - Rear Wiper is Inoperative > Page 12320 3. Use a torque wrench to measure the amount of torque necessary to rotate the wiper arm throughout the entire travel of the wiper arm. (Figure 3) a. This must be done while the glass is open so that the wiper mechanism is disengaged from the motor drive plate. b. The wiper blade should be in full contact with the glass throughout the entire stroke of the arm. c. The measurement taken must not exceed 49 lb-in (5.5 N.m) of force when rotated in either direction. (1) If the force is greater than 49 lb-in (5.5 N.m), then replace the rear window striker / wiper pivot shaft assembly. Refer to Workshop Manual, Section 501-16 - Wipers and Washers Removal and Installation. (Figure 4) (2) If the rear window striker/wiper pivot shaft assembly is within specification, then follow normal Workshop Manual diagnostics. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiper Motor Linkage: > 07-10-13 > May > 07 > Wipers/Washers - Rear Wiper is Inoperative > Page 12321 IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071013A 2003-2007 0.7 Hr. Expedition/Navigator: Replace The Rear Window Striker/Wiper Pivot Shaft, Includes Time To Verify Concern (Do Not Use With 40860B) DEALER CODING CONDITION BASIC PART NO. CODE 17C426 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiper Motor Linkage: > 07-10-13 > May > 07 > Wipers/Washers - Rear Wiper is Inoperative > Page 12327 3. Use a torque wrench to measure the amount of torque necessary to rotate the wiper arm throughout the entire travel of the wiper arm. (Figure 3) a. This must be done while the glass is open so that the wiper mechanism is disengaged from the motor drive plate. b. The wiper blade should be in full contact with the glass throughout the entire stroke of the arm. c. The measurement taken must not exceed 49 lb-in (5.5 N.m) of force when rotated in either direction. (1) If the force is greater than 49 lb-in (5.5 N.m), then replace the rear window striker / wiper pivot shaft assembly. Refer to Workshop Manual, Section 501-16 - Wipers and Washers Removal and Installation. (Figure 4) (2) If the rear window striker/wiper pivot shaft assembly is within specification, then follow normal Workshop Manual diagnostics. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiper Motor Linkage: > 07-10-13 > May > 07 > Wipers/Washers - Rear Wiper is Inoperative > Page 12328 IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071013A 2003-2007 0.7 Hr. Expedition/Navigator: Replace The Rear Window Striker/Wiper Pivot Shaft, Includes Time To Verify Concern (Do Not Use With 40860B) DEALER CODING CONDITION BASIC PART NO. CODE 17C426 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Service and Repair > Wiper Mounting Arm and Pivot Shaft - Windshield Wiper Motor Linkage: Service and Repair Wiper Mounting Arm and Pivot Shaft - Windshield WIPER MOUNTING ARM AND PIVOT SHAFT - WINDSHIELD Removal and Installation 1. Remove the cowl grille panel. 2. Disconnect and position the hood light harness aside. 3. Remove the hood struts. - Using a suitable tool support the hood. 4. Remove the mounting arm and pivot shaft assembly. 1 Disconnect the electrical connector and position the wiring harness aside. 2 Remove the bolts. - To install, tighten to 8 Nm (71 lb-in). 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Service and Repair > Wiper Mounting Arm and Pivot Shaft - Windshield > Page 12331 Wiper Motor Linkage: Service and Repair Wiper Mounting Arm and Pivot Shaft - Rear WIPER MOUNTING ARM AND PIVOT SHAFT - REAR Removal and Installation 1. Remove the rear wiper pivot arm. 2. Remove the dust boot cover. 3. Remove the nut and the rear window glass handle. - To install, tighten to 18 Nm (13 lb-ft). 4. Remove the nuts and the rear window wiper striker and wiper pivot shaft assembly. - To install, tighten to 6 Nm (53 lb-in). 5. To install reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Service and Repair > Wiper Mounting Arm and Pivot Shaft - Windshield > Page 12332 Wiper Motor Linkage: Service and Repair Wiper and Washer System - Exploded View WIPER AND WASHER SYSTEM - EXPLODED VIEW Wiper And Washer System - Front Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Service and Repair > Wiper Mounting Arm and Pivot Shaft - Windshield > Page 12333 Wiper And Washer System - Rear Removal And Installation 1. For additional information, refer to the procedures. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Technical Service Bulletins > Customer Interest for Wiper Pivot: > 07-10-13 > May > 07 > Wipers/Washers - Rear Wiper is Inoperative Wiper Pivot: Customer Interest Wipers/Washers - Rear Wiper is Inoperative TSB 07-10-13 05/28/07 REAR WIPER INOPERATIVE FORD: 2003-2007 Expedition LINCOLN: 2003-2007 Navigator This article supersedes TSB 06-22-10 to update the vehicle model years. ISSUE Some 2003-2007 Expedition and Navigator vehicles, the rear wiper may not return to park position. In this case, the rear wiper system will attempt to park periodically causing a battery drain.This concern may be caused by corrosion on the wiper pivot shaft assembly. ACTION Use the following Service Procedure to identify and replace the rear window striker/wiper pivot shaft assembly. SERVICE PROCEDURE 1. Disengage rear wiper mechanism by partially opening the rear liftgate glass. (Figure 1) 2. Access the rear wiper arm attaching nut. (Figure 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Technical Service Bulletins > Customer Interest for Wiper Pivot: > 07-10-13 > May > 07 > Wipers/Washers - Rear Wiper is Inoperative > Page 12342 3. Use a torque wrench to measure the amount of torque necessary to rotate the wiper arm throughout the entire travel of the wiper arm. (Figure 3) a. This must be done while the glass is open so that the wiper mechanism is disengaged from the motor drive plate. b. The wiper blade should be in full contact with the glass throughout the entire stroke of the arm. c. The measurement taken must not exceed 49 lb-in (5.5 N.m) of force when rotated in either direction. (1) If the force is greater than 49 lb-in (5.5 N.m), then replace the rear window striker / wiper pivot shaft assembly. Refer to Workshop Manual, Section 501-16 - Wipers and Washers Removal and Installation. (Figure 4) (2) If the rear window striker/wiper pivot shaft assembly is within specification, then follow normal Workshop Manual diagnostics. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Technical Service Bulletins > Customer Interest for Wiper Pivot: > 07-10-13 > May > 07 > Wipers/Washers - Rear Wiper is Inoperative > Page 12343 IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071013A 2003-2007 0.7 Hr. Expedition/Navigator: Replace The Rear Window Striker/Wiper Pivot Shaft, Includes Time To Verify Concern (Do Not Use With 40860B) DEALER CODING CONDITION BASIC PART NO. CODE 17C426 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Pivot: > 07-10-13 > May > 07 > Wipers/Washers - Rear Wiper is Inoperative Wiper Pivot: All Technical Service Bulletins Wipers/Washers - Rear Wiper is Inoperative TSB 07-10-13 05/28/07 REAR WIPER INOPERATIVE FORD: 2003-2007 Expedition LINCOLN: 2003-2007 Navigator This article supersedes TSB 06-22-10 to update the vehicle model years. ISSUE Some 2003-2007 Expedition and Navigator vehicles, the rear wiper may not return to park position. In this case, the rear wiper system will attempt to park periodically causing a battery drain.This concern may be caused by corrosion on the wiper pivot shaft assembly. ACTION Use the following Service Procedure to identify and replace the rear window striker/wiper pivot shaft assembly. SERVICE PROCEDURE 1. Disengage rear wiper mechanism by partially opening the rear liftgate glass. (Figure 1) 2. Access the rear wiper arm attaching nut. (Figure 2) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Pivot: > 07-10-13 > May > 07 > Wipers/Washers - Rear Wiper is Inoperative > Page 12349 3. Use a torque wrench to measure the amount of torque necessary to rotate the wiper arm throughout the entire travel of the wiper arm. (Figure 3) a. This must be done while the glass is open so that the wiper mechanism is disengaged from the motor drive plate. b. The wiper blade should be in full contact with the glass throughout the entire stroke of the arm. c. The measurement taken must not exceed 49 lb-in (5.5 N.m) of force when rotated in either direction. (1) If the force is greater than 49 lb-in (5.5 N.m), then replace the rear window striker / wiper pivot shaft assembly. Refer to Workshop Manual, Section 501-16 - Wipers and Washers Removal and Installation. (Figure 4) (2) If the rear window striker/wiper pivot shaft assembly is within specification, then follow normal Workshop Manual diagnostics. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Pivot: > 07-10-13 > May > 07 > Wipers/Washers - Rear Wiper is Inoperative > Page 12350 IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071013A 2003-2007 0.7 Hr. Expedition/Navigator: Replace The Rear Window Striker/Wiper Pivot Shaft, Includes Time To Verify Concern (Do Not Use With 40860B) DEALER CODING CONDITION BASIC PART NO. CODE 17C426 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Technical Service Bulletins > Page 12351 Wiper Pivot: Service and Repair REAR WINDOW STRIKER AND WIPER PIVOT SHAFT ASSEMBLY Removal 1. Remove the rear wiper pivot arm. 2. Remove the dust boot cover. 3. Remove the nut and the rear window glass handle. 4. Remove the nuts and the rear window striker and wiper pivot shaft assembly. Installation 1. Remove the liftgate trim panel. 2. NOTE: An audible click should be heard as the striker engages the latch. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Technical Service Bulletins > Page 12352 Push the rear window wiper striker and pivot shaft assembly into the wiper motor. The pivot shaft pin should be aligned with the hole in the motor disc. 3. Install the rear window wiper motor alignment tool. If installing a new rear wiper motor, one is provided with the motor assembly. 1 Make sure the alignment tool fits over the motor disc and striker assembly. 2 Make sure the alignment tool clips are securely engaged. 4. Carefully close the liftgate glass. 5. Open the liftgate. Install the rear window wiper striker and wiper pivot arm mounting assembly nuts. Tighten to 6 Nm (53 lb-in). 6. Remove the rear window wiper motor alignment tool. 7. Close the liftgate. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Technical Service Bulletins > Page 12353 8. Install the rear window wiper pivot shaft nut and handle. Tighten to 18 Nm (13 lb-ft). 9. Install the dust boot cover. 10. NOTE: This step makes sure that the wiper motor is in the PARK position. Turn the rear window wiper switch ON and allow the motor to operate for at least one cycle. Turn the rear window wiper switch to OFF. 11. Install the rear wiper pivot arm onto the rear window wiper motor shaft. 1 Position the wiper pivot arm onto the rear window wiper motor shaft. 2 Tighten the nut to 15 Nm (11 lb-ft). 3 Install the cover. 12. Open the liftgate. 13. Install the liftgate trim panel. 14. Test the liftgate and liftgate glass for normal operation. Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations View 151-14 (Steering Column) Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 12357 Wiper Switch: Diagrams C202a C202b Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 12358 C202c Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 12359 Wiper Switch: Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L VIN 5 (2006)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 12360